RU2738690C1 - Method for production of decorative composite material based on mammoth bone - Google Patents

Abstract

FIELD: technological processes.SUBSTANCE: invention relates to production of mammoth bone workpieces for making decorative and decorative articles, for example panels, panels, mosaics and door handles. Method for producing decorative composite material based on mammoth bone is characterized by that as filler used ivory bones (pieces), and the matrix is a synthetic binder (epoxy resin), for which at the preliminary preparation stage, the mammoth bone pieces are sorted according to the texture, hue and size, molding mass is prepared by combining with binder in mixer at drum rpm of not more than 20 rpm for 5-10 minutes and composite material is obtained in mold by cold pressing at specific pressing pressure of 0.6-0.8 MPa, molding temperature 25-30°C and holding under pressure for 20-24 hours, with the following ratio of components, wt%: filler of tusk pieces 85-90, synthetic binder 10-15.EFFECT: produced material has good strength properties required for subsequent manufacture of carved items on their basis.1 cl

Description

The invention relates to the production of blanks in the form of blocks using mammoth bone, in particular, decorative production waste in the form of bone pieces, on the basis of which artistic and decorative products are made, for example, panels, panels, mosaics, door handles, handles of knives and tools, stationery accessories, stands and more.

In the field of making decorative items from natural materials, first of all, there are known methods of making elements with the use of minerals, decorative stones, for example, by cutting a stone into blanks with subsequent processing (see Orlov A.M. Processing of natural decorative stone. M., 1956 ; RU No. 2154580, class В44С 5/04, В28D 1/02, publ. 20.08.2000).

The known technical solutions do not help to minimize the generated volume of waste, a significant amount of which is processed into crumb or rejected.

Known solutions aimed at the disposal of mineral waste products, for example, by using them as fillers.

According to the method of making tiles for decorative picturesque panels (see SU No. 473624, class B44C 5/04, publ. 06/15/1975), a layer of transparent resin is poured into a mold with a glossy bottom (for example, made of plexiglass), which is sprinkled with vermiculite of large fractions with a size of 10-15 mm, then pour a layer of a mixture of resin with vermiculite fractions of 10 mm and sprinkle with fine dry vermiculite to create a rough tile surface. After curing, the tiles are removed from the mold.

In addition, there is a known method of making decorative items using a filler made of amber (see RU No. 2151700, class В44С 5/00, C04B 26/18, publ. 06/27/2000), according to which a decorative composite material based on a polymer binder and filler made of low quality amber or amber production waste.

Known solutions involve the use of natural minerals and are not intended for the manufacture of decorative items using bone material.

Bone, as the most stable of organic compounds, has long found great practical applications, both for making household crafts and for decoration.

It is known that mammoth tusk is the only high-value bone material permitted for harvesting and use. The physical qualities of the mammoth tusk massif are unique and modern technologies fail to artificially fully recreate the properties of the natural mammoth bone. Meanwhile, mammoth bone is limited in volume, from year to year it is mined in more difficult conditions, which leads to an increase in the cost of production of decorative items using bone material.

For the manufacture of products from mammoth ivory, first of all, bones of a homogeneous structure are used, which have a uniform color of the massif, with the absence of cracks and other defects. At the same time, production is accompanied by the release of a significant amount of bone waste, the volume of which, according to some estimates, can reach up to 60-80%, depending on the initial quality of bone raw materials.

The problem to be solved by the claimed solution is to obtain a decorative composite material based on mammoth bone, which has special decorative properties inherent in organic texture materials with a good visual effect.

The technical effect obtained when solving the problem is expressed in the utilization of waste from bone carving production, expanding the range of decorative composite materials. Moreover, in addition to decorativeness, the new material has good strength properties necessary for the subsequent manufacture of carved products on their basis.

To solve this problem, the method of obtaining a decorative composite material based on mammoth bone is characterized by the fact that pieces of ivory are used as a filler, and a matrix is a synthetic binder (epoxy resin), for which, at the stage of preliminary preparation, crushed pieces of tusk are sorted by texture, shade and by size, the molding mass is prepared by combining (mixing) with a binder in a mixer at a drum rotation frequency of no more than 20 rpm for 5-10 minutes and a composite material is obtained in a mold by cold pressing at a specific pressing pressure of 0.6- 0.8 MPa, pressing temperature 25-30 ° C and holding under pressure for 20-24 hours, with the following ratio of components, wt. %: filler from tusk pieces - 85-90, synthetic binder - 10-15.

Comparative analysis of the features of the claimed solution with the known features of analogues indicates the compliance of the declared solution with the "novelty" criterion.

The set of features of the invention provides a solution to the stated technical problem, namely, obtaining a new decorative composite material using bone waste from mammoth ivory in the form of blanks-blocks, which retains the special advantages of decorative and physical and mechanical properties inherent in mammoth ivory, in particular, the effect of inner glow, warm shades of a living body, unsurpassed plasticity of the smallest details, etc.

According to the claimed solution, the composite decorative material is a workpiece in the form of a block obtained by molding and pressing a composite mixture based on a synthetic polymer and a filler from pieces of mammoth bone.

Thus, the technological process of manufacturing a composite material includes the following main stages:

- preparation of the matrix (binder);

- filler preparation;

- combination of components;

- molding a briquette in a mold;

- cold pressing of the block;

- mold stripping;

- final mechanical processing of the received blocks, packing and storage.

As a binder, synthetic resins are used, which provide a high-strength, water-resistant, durable and transparent connection. For experimental work, samples based on epoxy and polyester resins were studied. From the point of view of safety, environmental friendliness and performance indicators, materials based on epoxy resin were determined as the most acceptable.

It is known that mammoth tusk is conventionally divided into five types of varieties (see http://koptelovy.ru/mammoths/klassifikaciya-bivnya-mamonta): collection, first, second, third and fourth varieties. If of them tusks from the first to the third grade are generally suitable for bone carving production, then the fourth grade, as a rule, includes wood chips, i.e. a tusk containing many cracks, suitable for making small items. The largest amount of waste is obtained from them in the form of pieces, bark of different sizes.

For the manufacture of a composite material, pieces of mammoth bone of various sizes and shades are used, obtained from any kind of ivory, mainly substandard production wastes. At the same time, the pieces can be specially selected by the artist, based on the idea of a future composition based on this material.

The stated solution is implemented as follows.

Pieces of ivory are pre-washed and sorted by size, texture, shades and dried under natural conditions for 48-72 hours or with some heating in a drying chamber with forced air circulation at a temperature not exceeding 35-36 ° C for 36-40 hours.

Selected dry lumps are weighed and placed in mixing equipment, which is used as standard drum mixers, for example, type СБН "Gambit" (see https://gambitmarket.ru) with adjustable drum rotation frequency. In order to exclude additional crushing of pieces of mammoth bone during mixing and to simplify equipment maintenance, the inner surface of the mixer drum can be equipped (sheathed) with a plastic lining.

Depending on the total weight of the bone pieces loaded into the drum of the mixer, the required amount of binder is weighed out, which is 10-15% of the total weight of the filler. As a binder, an epoxy resin is used, for example, of the ED or Epoxy type, with a hardener used according to the instructions for the resin. A certain colorant may be added to the resin to provide additional decorative properties.

With a slow rotation of the drum (no more than 20 rpm), a binder solution is gradually fed into the mixer through the loading window and the components are mixed for no more than 5-10 minutes. The finished mixture is discharged into a pallet or container.

For forming the preform, molds of a known collapsible design are used. The dimensions of the inner cavity of the mold determine the dimensions of the pressed block of the composite material. Before placing the mixture, the inner walls of the mold are covered with a protective release layer, for example, PET based films are used for this. In addition, the protective film also partially prevents the liquid resin from flowing out during molding and pressing.

The mixture is loaded into the mold manually or performed on a vibration platform. The manual method is convenient in that the molder can specifically determine the location of the pieces in the block mass. As a rule, pieces of mammoth tusk are placed parallel to each other, for example, along the fibers.

Depending on the volume of the block (mainly the thickness of the block), molding can be performed with layer-by-layer compaction of the mass, for which, a first layer with a thickness of, for example, 15-20 mm is placed in the mold, then the layer is covered with a film and carefully compacted by pre-pressing in a press , the specific pressing pressure is no more than 0.3-0.4 MPa.

After pre-pressing of the first layer, the protective film is removed and the next layer of the mass is applied in a similar way and pre-pressed in a known manner. When pre-pressing, excessive crushing of bone pieces is excluded.

Upon reaching the final thickness of the mass in the mold, the package is covered with a protective film, placed in a cold press of periodic action and the workpiece is pressed. Pressing modes: specific pressure 0.6-0.8 MPa, temperature 20-25 ° C, holding time under pressure - 24 ± 2 hours. To accelerate the pressing process, it is possible to use heating the package up to 30-35 ° C using well-known technical approaches. In this case, gluing the block can be completed within 18-20 hours.

During pressing in the package, the final pressing of the mass in the mold takes place, while the liquid resin fills the voids between the pieces of mammoth bone, completely enveloping them and giving solidity to the block of material being produced. After setting, the polymer binder does not shrink.

After the pressing time has elapsed, the pressure is released and the mold is stripped, the walls of which are freed from the protective film, and, after cleaning, are sent for reuse.

The resulting block of decorative composite material is inspected for damage, cleaned from gluing irregularities, if necessary, sent for final machining (scraping, grinding, trimming), then packed and stored.

An example of the implementation of the claimed method for producing decorative composite material based on mammoth bone.

For experimental work, a block was made with dimensions in length, width and thickness, respectively: 350x350x200 mm.

Epoxy 520 epoxy resin with hardener and without dye was used as a binder.

As a filler, dry pieces of ivory of approximately the same size (length up to 50 mm, width up to 30 mm, thickness up to 20 mm), differing in texture and shades, were selected. For a given block size, the calculated amount of filler was about 20 kg, based on which the required amount of resin was determined at 3 kg.

The selected bone pieces were placed in a drum-type mixer and at a drum rotation frequency of 20 rpm, they were gradually poured with a weighed amount of epoxy resin. Mixing was carried out for 5-10 minutes. The finished mixture was unloaded into a clean container, from where it was placed into a pre-assembled mold with a protective film, where a briquette was formed in several layers using periodic pre-pressing.

During molding, pieces of mammoth bone were placed along the fibers, and, to give decorative properties, some of them were alternated according to their external shades.

The loaded mold was placed in the interplate space of a periodic hydraulic press of the P-100 type and pressing was performed at a specific pressing pressure of 0.8 MPa for 24 hours at a room temperature of 25 ± 2 ° C. The magnitude of the external pressure should not contribute to excessive crushing of bone pieces.

The next day after releasing the pressing pressure, the mold was stripped and the glued block of material was unloaded. When evaluating the external properties, the unique decorative properties of the material were noted, due to the characteristic combination of a natural component from ivory and a synthetic stone made of epoxy resin.

The manufactured block had the following physical and mechanical properties: volume 23250 cm ³ , density 945.5 kg / m ³ (according to GOST 12730.1-78), compressive strength 87 MPa (according to GOST 10180-2012), ultimate strength in static bending - 95 MPa (according to GOST 10180-2012).

Thus, the resulting composite material, possessing unique decorative properties, is strong enough, which contributes to durability, the material is not exposed to UV rays and is convenient for subsequent processing and manufacture of products. At the same time, the claimed technical solution makes it possible to utilize a significant amount of industrial waste of mammoth bone, expanding the range of products based on it.

Claims (2)

A method of obtaining a decorative composite material, characterized in that crushed pieces of tusk are used as a filler, and a matrix is a synthetic binder, for which, at the stage of preliminary preparation, pieces of tusk are sorted by texture, shade and size, a molding mass is prepared by combining the filler with a binder and get a composite material by cold pressing in a mold at a specific pressure of 0.6-0.8 MPa and holding under pressure for 20-24 hours, with the following ratio of components, wt. %: tusk filler 85-90 synthetic binder 10-15