西班牙专利ES2713776A1 METHOD AND SYSTEM OF PRODUCTION OF BOARDS, SLABS OR ARTIFICIAL STONE PLATES WITH EFFECT OF WIDE VEGA

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专利摘要:
The present invention relates to a method and a system for the production of boards, slabs or plates of artificial stone, with effect of wide veins, which comprise inorganic particles of different sizes and hardened binders, and which simulate the appearance presented by some natural stones, as well as the boards, slabs or plates of artificial stone obtained by means of said method and system. (Machine-translation by Google Translate, not legally binding)
公开号:ES2713776A1
申请号:ES201731349
申请日:2017-11-22
公开日:2019-05-23
发明作者:Garcia Salvador Cristobal Rodriguez；Perez Carmen Maria Montero
申请人:Cosentino Research and Development SL；
IPC主号:

专利说明:

[0001]
[0002] Method and system of production of boards, slabs or plates of artificial stone with effect of wide veins.
[0003]
[0004] FIELD OF THE INVENTION
[0005]
[0006] The present invention relates to a method and a system for the production of boards, slabs or plates of artificial stone, with effect of wide veins, which comprise inorganic particles of different sizes and hardened binders, and which simulate the appearance presented by some natural stones.
[0007]
[0008] BACKGROUND OF THE INVENTION
[0009]
[0010] In construction and decoration, it is usual to use natural stone panels, such as for example marble, granite, steatite or travertine boards, due to their aesthetic qualities as well as their great resistance.
[0011]
[0012] However, natural stone can be an expensive and expensive raw material, due to difficulties in its extraction or elaboration, and certain types have a limited availability; in addition, it has limitations in terms of its color, which is reduced to those found in nature, and in terms of the reduced consistency of color patterns, since these are generated randomly in nature. Likewise, natural stone has limitations in performance such as its low resistance to abrasion or chemical attacks (eg acids), or its high stainability.
[0013]
[0014] To respond to this problem, it is usual the industrial manufacture of artificial stone panels, which mimic the aesthetics of artificial stone panels. In general they are obtained by mixing inorganic particles, usually of lapldeo origin, of different sizes, mixed with binders that can be hardened by different methods; depending on the binder used, it may be necessary to add catalysts or accelerators to achieve hardening, for example, certain resins. Additives such as dyes can also be added to said mixtures, depending on the desired final aesthetic. The proportion in weight of binder in the mixture is usually of 5-15%, and of inorganic particles of 70-95% with respect to the total mixture; Due to these composition ranges, the mixture of inorganic particles and binder before hardening acquires a texture similar to wet sand, with some stickiness and with a high tendency to form aggregates and to clump together. After mixing and homogenization, the mixture of particles and liquid binder (not hardened) is transported from the mixers to a distributor, which discharges the mixture onto a rectangular mold. The mold is formed in its base and its cover by sheets of Kraft paper or elastomer, while the sides of the mold are usually a metal frame or elastomer. Once the desired amount of mixture has been deposited on the base and inside the mold frame, the dough is covered with a lid (paper sheet or elastomer) and transported to a vibrating press station with vibration (vibrocompression to the ford ), to compact and extract the maximum possible air of the mixture, which is then subjected to the treatment necessary to harden the binder and obtain an artificial stone board with sufficient hardness. For example, in case the binder is a resin, the compacted mixture is taken to a curing oven, where the resin hardens at a temperature that usually varies between 70-120 ° C, normally with catalyst assistance added initially To the mix. After curing, the hardened mass is cooled, cut and calibrated to the required dimensions, and polished by at least one of its two largest surfaces (usually the top surface).
[0015]
[0016] However, these boards of artificial stone have the disadvantage that aesthetically the difference can be appreciated with the boards of natural stone, resulting with an artificial appearance. This is mainly due to the fact that the inorganic particles, although having different colors, are distributed more or less regularly throughout the material, lacking the typical grain of materials such as for example marble (calacatta, marquina, statuary), some types of granite, soapstone or travertines.
[0017]
[0018] In order to imitate these color patterns found in natural stones, different techniques of decoration of artificial stone boards have been developed. Such techniques include the application of pigments or colorants, solids or liquids, in different stages of the process, either in the liquid resin, superficially in the unhardened mixture layer, or in the interior of that mixture. The techniques used are diverse, and include for example the projection of pigment on the uncured mass, in the distributor or already deposited in the mold (see, for example, EP1905749 B1 and US20040032044 A1), or the combination of mixtures layers that they include different composition and / or colorants (see, for example, US9186819 B1 or EP2944443 A1).
[0019]
[0020] The creation of effects in this type of materials simulating irregular wide veins, particularly veins with regions of a width greater than a centimeter of thickness in the finished product, and extending to the full thickness of the board, of the type found in natural marbles, remains, however, a difficult and expensive task. The methods in this sense described in the state of the art require working with at least two different templates, which present hollow areas and branches or islands between those areas (see, for example, WO2016123433 A1 and EP3095768 A1). In addition to two templates, two distributors are also necessary, and all the elements must be positioned and removed in a synchronized manner, which requires a high investment and a large space in the production lines. The first template is used to form a series of cavities or ditches in a first mixture discharged by a distributor on that template. Thus, the gaps of the first template are filled by the first mixture, and cavities are generated in correspondence with the branches or islands in that template. The cavities or ditches created in the first mixture are then filled with a second mixture, of different composition and / or coloration, discharged by a second distributor and through a second template. For example, in WO2016123433 A1, this step of filling the cavities is carried out with a second template complementary to the first, which has islands in the positions where the first template has gaps, covering in these areas the first mixture, both in its upper and lateral surface, and in holes where the first template has islands, so that the holes can be filled with the second mixture. Once the cavities have been filled, the second template is removed and the combination of first and second mixes is covered with the lid of the mold and the usual steps of compaction, hardening and finishing are continued. For its part, in EP3095768A1, the step of filling the cavities is carried out with a second template, in this case a flat template, which has material in the positions where the first template has gaps, covering in these areas the surface of the first mixture, and gaps, coinciding with the islands of the first template, so that the gaps with the second mixture can be filled. In both cases, the second mixture is distributed throughout the width and length of the first template, so only a part of the mixture enters the holes present in the templates, leaving the rest of the mixture on the solid parts of the templates; This surplus material has to be cleaned, generating significant losses, or there is a risk that it ends up falling randomly over areas of the first mixture, contaminating it and creating defects in the items produced. In addition, when discharging the second mixture through the second template, at the time of removing the second template, the first and second mixture of inorganic particles and binder intermingle at the edges of the cavities, leading to a low definition of the veins obtained, that is to say, the edges of the vein remain unclear, blurred.
[0021]
[0022] Document EP3095768A1 further describes the formation of fine veins, by applying an impregnation material on small cavities (depth 3/10 -4/10 of the total thickness of the artificial stone) created previously on the surface of the mixture of inorganic particles and resin , corresponding to fine veins, by means of an automated arm provided with a projection head at one of its ends. The impregnation mixture, to be able to be projected onto the cavities, must consist of a hardenable fluid, which must not comprise any type of ground particles, or at most can comprise micronized particles, with a grain size between 0.1 - 750 micrometers, and never more than 750 micrometers. After the small cavities have been impregnated, they collapse and close, for example, by rolling a roller on the surface. After this procedure, proceed in the usual way to harden the binder and obtain an artificial stone board, only with fine veins, or with fine and wide veins, where the wide veins have been produced as described in the previous paragraph.
[0023] According to the foregoing, the methods of the state of the art for obtaining artificial stone boards have several drawbacks that are of interest, such as the cost of production for the machinery involved, or the defects that the material obtained in many cases presents, because to the little definition of the veins obtained, or due to the contamination of the first mixture by the portions of the second mixture undesirably put on it.
[0024]
[0025] Therefore, there is a need to develop an alternative method that allows the obtaining of artificial stone boards in an efficient manner with broad vein effect, with lower shrinkage and better quality of the final product, and in general, that does not suffer from the problems of the methods known so far.
[0026]
[0027] SUMMARY OF THE INVENTION
[0028]
[0029] The present invention solves the drawbacks of the methods of the state of the art, providing a method for the production of panels, slabs or plates of artificial stone with vein effect, particularly broad veins, which comprise inorganic particles of different sizes and a binder hardened, and that simulate the appearance of some natural stones, so! as a cavity filling system that is suitable and that allows to carry out said method.
[0030] The method and the filling system within the scope of the invention are particularly suitable for producing wide veins, with regions of the grain with a width of at least 0.5 cm, or at least 1 cm, in the product obtained after the stages of compacted and hardened.
[0031]
[0032] According to a first aspect of the invention, this therefore relates to a method of manufacturing panels, slabs or plates of artificial stone with a grain effect, preferably wide veins; said method comprises the following steps:
[0033] a) a template is positioned on a surface, which comprises hollows and islands, preferably irregular, where the islands correspond to at least one vein of the article to be manufactured;
[0034]
[0035] b) a first mixture, which comprises inorganic particles and an unhardened binder, is discharged onto the template, by means of a first distributor device, so that said first mixture rests on the surface and fills at least part of the template holes ;
[0036]
[0037] c) the template is removed, obtaining a layer of the first mixture with cavities in said layer, defined by the positions of the islands of the template;
[0038]
[0039] d) a second mixture, which comprises inorganic particles and an uncured binder, is discharged to fill said at least part of the cavities in the first mixture layer with said second mixture;
[0040]
[0041] e) the resulting layer of the combination of first and second mixtures is compacted, preferably by vibration and / or compression and / or vacuum, and a hardening process is carried out, to obtain the artificial stone board, slab or sheet with vein effect, preferably wide veins;
[0042]
[0043] where in step d) said second mixture is discharged in a localized manner over the cavities in the layer of the first mixture, by means of a second distributor device, which comprises a manifold, whose lower opening has, in at least one direction, a width less than or equal to the maximum width of the cavities, said second device moving along the cavities, filling at least part of said cavities with the second mixture.
[0044]
[0045] In step b) of the method, the first mixture is discharged by filling at least part of the gaps in the template, preferably at least 30%, or at least 40%, or at least 50% of the total volume of gaps in the template. that template.
[0046]
[0047] In step d) of the method, the second mixture fills at least part of the cavities in the first mixture layer, preferably at least 50%, or at least 65%, or at least 80% of the volume of all the cavities in said first mix layer. Preferably, each of the cavities present in the first mixture layer is filled, at least 50%, or at least 80% of its volume, with the second mixture.
[0048]
[0049] Another aspect of the present invention relates to boards, slabs or plates of artificial stone with wide grain effect, which have been obtained by the method described above. In another aspect, the invention relates to the use of the boards, slabs or plates of artificial stone with effect of wide streaks obtained, as construction material or decoration, for the manufacture of countertops, sinks, shower trays, wall coverings or floors, stairs or others.
[0050]
[0051] Furthermore, according to a further aspect, the present invention relates to a system suitable for manufacturing a board, slab or plate of artificial stone with broad streaks effect, which it fills, with a mixture of filler, which may comprise inorganic particles and binder. unhardened, cavities, preferably irregular, present in a first layer of substrate, system comprising a distributor device mounted on a robotic device, characterized in that the dispensing device comprises:
[0052]
[0053] i. a hopper to store the filling mixture, where the hopper has an upper opening and a lower opening,
[0054] ii. a conveyor belt located under the lower opening of the hopper, and iii. a collector, with an upper and lower opening, which collects the filling mixture discharged from the conveyor belt and deposits it in the cavities to be filled from the substrate. The collector preferably has a lower opening with a width less or equal, in at least one direction, than the maximum width of the cavities to be filled.
[0055]
[0056] Although the system of filling cavities in a substrate, according to this aspect of the invention, is particularly suitable for the production of artificial stone boards composed of inorganic particles and hardened binder, its use is not limited to this application, and this The system could also be used in production processes of other materials, such as ceramic materials, where cavities are generated in a substrate and it is desired to fill in a localized manner with a filling mixture with a tendency to aggregate.
[0057]
[0058] The relative terms of position, such as superior, inferior, above, below, etc. used during the description refer to the position in height relative to the ground or the surface on which the production line that carries out the method of the invention or comprising the system or device of the invention. In the same way, the terms vertical or horizontal refer to directions as they are understood in a natural way, that is, horizontal is the direction essentially parallel to the ground plane, and vertical is the direction perpendicular to that plane.
[0059]
[0060] DESCRIPTION OF THE FIGURES
[0061]
[0062] In the following, the figures and their elements are described; said figures are illustrative in order to facilitate the understanding of the invention, however, in no case should they be interpreted in a limitative manner for the scope of the invention.
[0063]
[0064] FIG. 1- Exploded view in perspective of the elements of the method of the invention, with the template (2) raised on the surface (1): surface (1) with optional Kraft paper, template (2), optional frame (21) included in the template (2), islands (22) of the template (2) and holes (23) of the template (2).
[0065]
[0066] FIG. 2- Perspective mounted view of the elements of the method of the invention, corresponding to step a), with the template (2) positioned on the surface (1) and in contact with it: surface (1) with optional Kraft paper, template (2) with optional frame (21), islands (22) of the template (2) and holes (23) of the template (2)
[0067]
[0068] FIG. 3- Perspective mounted view of the elements of the method of the invention, corresponding to step b), where the holes (23) of the template (2) positioned on the surface (1) have been partially filled with the first mixture ( 3) from a first distributor (not shown): surface (1) with optional Kraft paper, template (2) with optional frame (21), islands (22) of the template (2), holes (23) of the template ( 2) and first mixture (3) (dotted areas show the holes already filled with the first mixture (3))
[0069]
[0070] FIG. 4- Perspective mounted view of the elements of the method of the invention: surface (1) with optional Kraft paper, template (2) with optional frame (21), islands (22) of the template (2), and recesses (23) ) of the template (2) already filled with the first mixture (3) (dotted areas), with exploded perspective of the compactor (4) with complementary shape with the form of template (3), used in the optional stage b1) of pre -compacted
[0071]
[0072] FIG. 5- Perspective view of the elements of the method of the invention, in step c) corresponding to the withdrawal of the islands (22) from the template (2), once the gaps (23) of the template (2) have been filled with the first mixture (3) (areas with more dotted intense). The cavities (5) left when removing the islands (22) from the template (2) and in correspondence with these (areas with less intense dotting) can be observed.
[0073] FIG. 6- Detailed view corresponding to step d) of the method of the invention, filling the cavities (5) with the second mixture (7), by moving the collector (6) along the cavities (5); the second mixture (7) is introduced by the upper opening (61) of the collector (6) and falls through the lower opening (62) of the collector (6) into the interior of the cavities (5).
[0074]
[0075] FIG. 7. Detailed view of the filling system according to a possible embodiment of the invention, mounted on a robotic device (not shown); filling the cavities (5) with the second mixture (7) or filling mixture; the second mixture (7) or filling mixture is introduced into the hopper (8) through its upper opening (81), this falls on a conveyor belt (9), which discharges the second mixture (7) into the collector (6) that is unloading located in the cavities (5) the second mixture (7). As a result, a layer of combination material of first and second mixtures is obtained.
[0076]
[0077] FIG. 8 and 9. Detailed view of the elements of a possible embodiment of the system according to an aspect of the invention, adapted to be mounted on a robotic device (not shown): hopper (8), upper opening (81) of the hopper ( 8), conveyor belt (9), manifold (6), upper opening of the collector (61) and lower opening (62) of the collector (6).
[0078]
[0079] FIG. 10.- Projections of possible shapes of the lower opening (62) of the collector (6) on the plane perpendicular to the direction of discharge (vertical direction), to illustrate the meaning of the smaller width (d) and the greater width (D) ). The form is not necessarily limited to that indicated in Figures 10A and 10B.
[0080]
[0081] DETAILED DESCRIPTION OF THE INVENTION
[0082]
[0083] During this description, and to facilitate the compression of the invention, reference will be made to the elements numbered in Figures 1-10, by way of illustration, without intending that this may entail any limitation or restriction to the scope covered by the claims or to its reach.
[0084]
[0085] The present invention relates to a method and a system for the production of panels, slabs or plates of artificial stone with the effect of veins, particularly broad veins, which comprise inorganic particles of different sizes and sizes. a hardened binder, and that simulate the appearance of some natural stones.
[0086]
[0087] A first aspect of the invention relates to a method of manufacturing boards, slabs or plates of artificial stone with wide grain effect; said method comprises the following steps:
[0088]
[0089] a) on a surface (1) a template (2) is positioned, which comprises hollows (23) and islands (22), preferably irregular, which correspond to at least one grain of the article to be manufactured;
[0090]
[0091] b) a first mixture (3), which comprises inorganic particles and a non-hardened binder, is discharged onto the template (2), by means of a first distributing device, so that said first mixture (3) rests on the surface (1) ) and fill at least part of the gaps (23) of the template (2);
[0092]
[0093] c) the template (2) is removed, obtaining a layer of the first mixture (3) with cavities (5) in said layer, defined by the positions of the islands (22) of the template (2);
[0094]
[0095] d) a second mixture (7), which comprises inorganic particles and an unhardened binder, is discharged, to fill with said second mixture (7) at least part of the cavities (5) in the first mixture layer (3);
[0096]
[0097] e) the resulting layer of the combination of first and second mixtures is compacted, preferably by vibration and / or compression and / or vacuum, and a hardening process is carried out, to obtain the artificial stone board, slab or sheet with vein effect, preferably wide veins;
[0098]
[0099] where in step d) said second mixture (7) is discharged in a localized manner over the cavities (5) in the layer of the first mixture (3), by means of a second distributor device, which comprises a manifold (6), whose lower opening (62) has, in at least one direction, a width (d) less than or equal to the maximum width of the cavities (5), said second device moving along at least part of the cavities (5), at least partially filling said cavities (5) with the second mixture (7).
[0100]
[0101] In a particular embodiment of the method, and as can be seen in Figures 1-5, the template (2) comprises a frame (21) that closes the islands (22) and the holes (23), of a size corresponding to the board, slab or artificial stone plate to manufacture, or superior. Alternatively, or additionally, the frame (21) may be an element separated from the rest the template, which is positioned on or removed from the surface (1) before, after or at the same time as the rest of the template.
[0102]
[0103] The above method allows to obtain boards, slabs or plates of artificial stone, with effect of wide veins filled with a second mixture (7) different from the first mixture (3) that defines the substrate of the board, slab or plate, veins that extend along a good part of the length and / or width of the article obtained, and preferably through all or most of the thickness of the article, for example more than 50% of the thickness, with a good definition at its edges.
[0104]
[0105] Both the first mixture (3) and the second mixture (7) comprise inorganic particles; said inorganic particles can come from natural or artificial materials, and can be obtained for example by crushing and / or grinding, to obtain different grain sizes. Today, inorganic particles can also be purchased from specialized companies that sell them already dried and fractionated according to their granulometry. The inorganic particles can be obtained from, for example, but not limited to, materials such as marble, dolomite, quartz (both opaque and clear), silica, glass, cristobalite, granite, porphyries, quartzites, sands sillceas, albita, basalt, ceramic, etc. Inorganic particles from a single material, or a mixture of particles from various sources, can be used in the same mixture. According to a particular embodiment, the inorganic particles comprise quartz particles, or in the mixture quartz particles are incorporated. The inorganic particles will have a granulometric distribution, that is, they will have a particle size that is in an interval. The inorganic particles included in the artificial stone article can be classified with respect to their granulometry into "aggregates" or "micronized" (powders). Aggregates are the portion with the largest particle size, usually greater than 0.5 mm and can reach several millimeters. The micronizados are in turn composed of finely divided particles, with a particle size that can range from 1 nanometer and up to 750 micrometers. The granulometry of both first and second mixtures may be similar or different, and the particle size will generally be in the range of 1 nanometer to 20 mm, preferably in a range of 0.1 micrometer to 10 mm. According to other particular embodiments, the particle size will be in a range of 0.2 to 5 mm, or 0.3 to 3 mm. Both first and second mixtures preferably incorporate a combination of inorganic particles that combine aggregates and micronized. The inorganic particles will suppose, in general, between 70 and 95% by weight of the respective mixture, preferably between 85 and 95%; the percentages, sizes and origin can be similar or different between one mix and another.
[0106]
[0107] The size distribution of the inorganic particles comprised in the first (3) or second (7) mixture can be determined by customary methods in the field of the invention. For example, this particle size distribution can be determined in accordance with ASTM C136-14 and ASTM C117-17.
[0108]
[0109] The mixtures, both the first and the second, also comprise at least one uncured binder, which is hardenable (or curable), in an amount of between 5 and 30% by weight, preferably 5 to 15% by weight, of binder with with respect to the total of the mixture; said binder (also called binder) will serve to achieve an irreversible cohesion and adhesion between the inorganic particles of the mixture, and finally providing a hardened board, slab or sheet. Said binder can be any binder which, after being hardened, finally provides a sufficient hardness to the obtained board, slab or sheet, achieving cohesion and adherence between the inorganic particles sufficient. The binders known in the state of the art are numerous, for example any of them can be used. Particularly suitable for the present invention are organic resins, such as polyester resins, but other types of binders can also be applied, such as, for example, inorganic binders such as cement, for example portland cement. For example, the resin that can be used in the framework of the present invention can be a heat-curing resin, that is to say, that is cured, hardens, by means of heat action, for example a treatment between 70 and 120 ° C. . Some examples of thermosetting resins are, but are not limited to, an unsaturated polyester resin, a methacrylate resin, an epoxy resin, vinyl resins, etc. Usually to achieve the curing of this type of resins in a practicable time it is necessary to add a suitable catalyst and / or accelerator, usually in a proportion between 0.1-5% by weight with respect to the weight of the binder, which will be incorporated into the mixture. corresponding in a stage of mixing, prior to the manufacture of the boards, slabs or plates of artificial stone. The binder used in any of the mixtures may be different or equal to each other. Preferably, it will have a similar composition in the first and second mixes, in order to prevent incompatibilities and optimize the adhesion between the materials, along the entire board, slab or sheet.
[0110]
[0111] Other additives can be added in any of the mixtures. The most common type of additive will be the use of dyes, usually metal oxides, to provide the desired color to the board, slab or final plate. It can be a mixture of dyes or be one. The amount of dye used will depend on the dye used and the intensity of color desired in the final product, but in general it will be between 0.1-10%, preferably between 1-5% by weight of the weight of the binder. Dye can be used in both mixtures, or only in one of them. In case of using dye in both mixtures, that is, the first and second mixtures, the dye or mixture of dyes, or their concentration, will be different between one mixture and the other, to achieve a sufficient contrast between the wide veins and the base material of the artificial stone.
[0112]
[0113] Other additives may also be added in any of the blends, such as cure accelerators or adhesion promoters between the filler and the resin (for example, but not limited to, silanes). This type of additives and their proportion used are known from the state of the art, and any of them can be incorporated in the present invention.
[0114]
[0115] The surface (1), on which the template (2) is positioned, is preferably a horizontal surface, which would normally be part of the industrial production line of the boards, slabs or plates. This surface (1), together with the template (2) and the frame (21) optionally included in the template (as a single body and / or as an element separated from the rest of it), form a mold containing the first mixture (3) downloaded by the first distributor. The surface (1), advantageously, comprises in the part that comes into contact with the first and / or second mixture, a sheet of Kraft paper or elastomer, for example an elastomer of EPDM, silicone or neoprene. This Kraft or elastomer paper can be used as a temporary support to advance the mixture deposited on the later stages of the production process, accompanying the mixture during the compaction and hardening. Once the board, slab or plate has hardened, the paper or elastomer sheet is removed by peeling or by calibration and polishing.
[0116]
[0117] It is provided in the invention that the template (2) can be formed from several separate elements, which are positioned on the surface (1) simultaneously or separately. As indicated, the template (2) used, according to a particular embodiment, will comprise (as a single body or as an element separated from the rest of the template) a frame (21) which will have, as a minimum, the shape and size of the board or slab that is intended to be obtained. The frame (21) will preferably have vertical walls to house the first mixture (3) on the surface (1), as a mold. In general, the length and width of the frame (21) will be somewhat greater than those of the board, slab or sheet to be manufactured, to compensate for the contraction that occurs during the stages of compaction and hardening, and to allow a more of the final piece, as well as to allow the final calibration and polishing, which will improve the qualities and final aesthetic appearance of the board or slab obtained. On numerous occasions, but not necessarily, it will be a frame (21) of rectangular shape, with a total height sufficient to accommodate enough material to obtain, after compaction of the mixtures and their hardening, a board, slab or plate of the desired thickness or greater. As indicated, according to particular embodiments, the frame (21) can be formed, alternatively or additionally, by an element physically separated from the rest of the template, which can be positioned on the surface before, after or at the same time the rest Of the template. In fact, this realization is preferred.
[0118]
[0119] Both the template (2) and the frame (21) optionally included in it (as a single body or as an element separated from the rest of the template), will be manufactured in a material sufficiently resistant to the attack of the components of the composition of any of the two mixtures used (mainly styrene vapors if a polyester resin is used), preferably stainless steel or polyamide, or they will be coated with materials resistant to said mixtures, for example with Kraft paper or an elastomer, similarly to the temporary support preferably included in the surface (1).
[0120]
[0121] The template (2) is designed in correspondence with the shape and size of the board, slab or artificial stone plate to be produced. Normally, this template (2) will comprise a frame (21) with vertical walls, where the recesses (23) and islands (22) are housed. The template (2), and the frame (21) optionally comprised therein, will usually have a rectangular shape, favorably with a length of at least 2 meters, preferably at least 2.5 meters and a width of at least 0.8 meters, preferably at least 1 meter. The vertical walls of the frame (21) will preferably have a total height suitable for housing the amount and volume of first mix (3) necessary to obtain the desired thickness of the artificial stone article after its compression, hardening and finishing. The total thickness of the frame (21) is at least 5 cm, preferably between 5 and 30 cm. The islands (22) (or branches) present in the template (2) preferably have an irregular and apparently random shape, which tries to simulate the shape of the veins found in the natural stones. These islands (22) therefore vary frequently in their dimensions along their length and along their thickness, they can be isolated from one another, or linked together, simulating the nature of the veins found in natural stones. The height of said islands (22) (or branches) will preferably be equal to or greater than the height of the vertical walls of the frame (21).
[0122] To discharge the first mixture (3) on the surface (1) with the template (2) positioned on it, said first mixture (3) is transported from a mixer, through conveyor belts, to a distributor, which for reasons of clarity and to differentiate it from the distributor device of the filling system of the cavities (5) (second distributing device), is here referred to as the first distributing device; said first distributing device discharges in a homogeneous manner the first mixture (3) on the template (2) positioned on the surface (1). The first mixture (3) falls from the first distributor device into the recesses (23) left by the template (2), resting on the surface (1), and at least partially filling the recesses (23), until reaching the desired thickness . Figure 3 shows the situation where approximately half of the template (2) has been filled with the first mixture (3). Preferably, the filling level of all the holes 23 is similar and homogeneous. This discharge with the first distributor device is carried out in a conventional manner, with control of the quantity of first mixture (3) discharged, and by techniques widely known in the art for this type of materials and processes. After this step, the first mixture (3) is retained within the gaps (23) of the template (2), between the islands (22) (or branches) and the frame (21) of the template (2), and deposited on the surface (1).
[0123]
[0124] Next, and as shown in Figure 5, the template (2) is removed from its position on the surface (1), preferably by elevation, with a layer of the first mixture (3) remaining on that surface (1), with cavities (5) (or recesses) where the islands (22) (or branches) of the template (2) were positioned. Due to the binder content of the first mixture (3), it has some coherence and stickiness, which causes the cavities (5) not to close when the template (2) is removed.
[0125] Then advance to the filling stage of the cavities (5), where it proceeds to discharge a second mixture (7), which also comprises inorganic particles and a non-hardened binder, to fill with said second mixture (7) at least part of the cavities (5) in the layer of the first mixture (3). As shown in Figure 6, this discharge is carried out in a localized manner on the cavities (5) in the layer of the first mixture (3), by means of a second distributor device, which comprises a manifold (6), whose lower opening (62) has, in at least one direction, a width (d) less than or equal to the maximum width of the cavities (5); said second distributor device travels along at least part of the cavities (5), preferably along all the cavities (5), filling at least partially, preferably at least 50%, said cavities (5) with the second mixture (7). In this way the discharge of the second mixture (7) occurs directly inside the cavities (5), without material loss and only contamination of the first mix parts (3). As the second mixture discharge (7) is located in the cavities (5), it can be achieved that the second mixture discharge (7) occurs from a small distance, that is, very close to the cavity (5), and in this way, in the artificial stone finally produced, a greater definition of the veins is obtained, since there is not so much dispersion of the second mixture (7) in the walls of the cavities (5) by the discharge from a greater height.
[0126]
[0127] With the characteristic that the width (d) of the lower opening (62) of the collector (6) is less or equal, in some direction, that the maximum width of the cavities (5) achieves the effect practiced by all of the discharged mixture falls into the cavities (5).
[0128]
[0129] The "width" (d) of the lower opening (62) of the collector (6) is understood to be its most common meaning, that is, the smallest distance through the geometric center between two opposite points on the inside that opening (62) , distance measured in the two-dimensional projection in a plane perpendicular to the direction of discharge through that aperture (62) .Asl, for example, if the aperture (62) is configured as a rectangle, and the mixture is vertically discharged through from it, the smaller width (d) of the opening (62) will be the length of the smaller side of the rectangle formed by the projection of the opening on a horizontal plane, in another example, if the opening (62) is configured inclined (not horizontal) and as an ellipse, by which the mixture is vertically discharged, the smaller width (d) of the opening will be the smaller diameter of the ellipse formed by the projection of the opening (62) on a horizontal plane. , the smaller width (d) of the lower opening r (62) of the manifold (6) will be less than or equal to 100 mm, or is comprised in a range from 20-80 mm, and more preferably between 30-70 mm. Figure 10 shows, as an example, by way of illustration, projections in a horizontal plane (XY) of options for the lower opening (62) of the manifold (6) shown in Figures 6-8, showing a smaller width (d) ) and a greater width (D).
[0130]
[0131] The width of the cavities (5) is understood as the distance between two facing points (opposite in a direction perpendicular to the direction following the cavity (5) located in the walls forming the cavities (5) obtained in the layer of the first mixture (3) when removing the template (2) The maximum width refers to the maximum distance between two pairs of those points faced, considering all the regions of all the cavities (5) produced by that template (2). width maximum of the cavities (5), preferably, will be greater than 10 mm, or between 10 -200 mm, and more preferably between 20-150 mm.
[0132]
[0133] According to a preferred embodiment, the second distributor device is mounted on a robotic device that moves said second distributor device along the cavities (5), preferably selectively, and discharges different quantities of the second mixture (7) into different regions of the cavities (5), according to the width of said cavities (5) in those regions. The different quantities discharged from the second mixture (7) are controlled by the speed of discharge of the second distributing device in the respective region of the cavities that are being filled, or by the speed of movement of the robotic device, depending on the respective region of the cavities that are being filled. Thus, the robotic device can be programmed to follow the irregular and apparently random shapes of the cavities (5) created by the islands (22) of the template (2) in the first mix layer (3), positioning the second device distributor so that it discharges the second mixture (7) mostly into the cavities (5). According to a preferred embodiment of the invention, the filling system is designed and adapted to discharge different quantities of the second mixture (7) in different regions of the cavities (5). While the robotic device displaces the second distributor device along the cavities (5), the dispensing device discharges different quantities of second mixture (7) in different regions of the cavities (5). In other words, the amount of second mixture (7) discharged can be adjusted to the volume to be filled that the cavity (5) has in the specific region being filled, where the robotic device positions the dispensing device. Preferably, there is a link between the robotic device and the distributor device, which allows synchronization between them, so that the quantity discharged from the second mixture (7) on the cavities (5) varies according to the position of the robotic device, in dependence on the width of the cavity (5) in said position. This link can be made through a computer system, through instructions given for example by programming.
[0134]
[0135] As can be seen in Figures 7-9, said second distributor device for filling the cavities (5) can preferably comprise a conveyor belt (9) for the second mixture (7), above the collector (6). ). This conveyor belt (9) can be, for example, an "endless" belt, which travels on a closed path on the outside of two or more cylinders, having a path through the top and back through the lower part, the second mixture (7) is deposited on the belt (9), and moves simultaneously with this, and upon reaching the part where the belt rotates to return, is discharged through the upper opening (61) of the collector (6), which directs the second mixture (7) towards the cavities (5), through its lower opening (62).
[0136]
[0137] In a particular embodiment, the speed of the conveyor belt (9) is kept constant, thus producing a discharge velocity of the second mixture (7) constant, while the speed of movement of the robotic device along the cavities ( 5) is varied, producing variations in the amount discharged in different regions of the cavities (5): smaller amount where the movement of the robotic device is faster, and more where the movement is slower. Alternatively, the speed of movement of the robotic device can be maintained constant along the cavities (5), while the speed of the conveyor belt (9) is varied along the displacement over the different regions of the cavities (5) . In this case, the quantity discharged from the second mixture (7) in a region of the cavities (5) will be greater, the higher the speed of the conveyor belt (9).
[0138]
[0139] The speed of the conveyor belt (9), the speed of the robotic device, and the position of the robotic device are preferably controlled by a computer processing system, and the instructions preferably given through programming.
[0140]
[0141] The preferred embodiment of the invention where the device for distributing the second mixture (7) comprises a conveyor belt (9), eliminates the limitations of other projection systems of known materials, in terms of the required fluidity of the mixture used for Fill. Thus, when the distributor device is based on the use of a conveyor belt (9), mixtures composed of binder aggregates with inorganic filler with a high particle content of granulometry> 0.75 mm can be used as a second mixture (7). ; in this way, these mixtures can be used to fill the cavities (5) that will define wide veins, without problems that the distributor becomes clogged or the mixtures can not be projected, as is the case, for example, of the system described in EP3095768A1 for the obtaining of fine veins in artificial stone. Thus, in a particular embodiment of the invention, the second mixture (7) discharged in step e) comprises at least 50%, preferably at least 65%, and more preferably between 70-95% by weight of the total mixture of particles inorganic with a granulometry greater than 0.75 mm.
[0142] The method, in foreseen embodiments of the invention, provides that the robotic device carries the second distribution device to a recharging position, where the quantity discharged from the second mixture (7) is replenished from the corresponding mixer, transported by means of a belt. The distributing device, according to a particular embodiment, comprises a filling level sensor, which indicates when it is necessary for the robotic device to proceed to the recharging position.
[0143]
[0144] According to a particular embodiment, after step b) of unloading and before step c) of removing the template (2), a precompacted stage b1) is carried out; in said step, the contents of the holes (23) left by the template (2) are processed, that is, the holes (23) in which the first mixture (3) is located, by means of a compactor (4), the which preferably comprises a plate complementary to the template (2), which presses the layer of the first mixture (3) against the surface (1). As can be seen in Figure 4, with an additional sheet with the template (2) it is meant to indicate that it is a plate with solid and hollow parts between them, in a complementary manner to the template (2) used, that is, it has of solid parts where the template has holes (23), and has holes where the template (2) has islands (22) (or branches), pressing only the areas containing first mixture (3). The compactor (4) will exert a pressure on the first mixture (3) sufficient to reach the desired level of compaction of that first mixture (3). The pressure exerted by the compactor (4) will be at least 0.5 kPa, preferably at least 1 kPa, and more preferably between 1.5 - 3.0 kPa.
[0145]
[0146] When applying pressure on the first mixture (3), the aggregates that compose it are compacted against the surface (1) and against the islands (22) in the template (2), eliminating part of the air included between them, and generating cavities ( 5) with more compact and stable walls when the template (2) is removed. This effect reduces the possibility that the components of the first mixture (3) and the second mixture (7) are intermixed in the walls of the cavities (5), during the filling stage of the cavities (5).
[0147]
[0148] Alternatively, or additionally to the pre-compacted step b1), an additional profiling step c1) can also be carried out, after step c) of removing the template (2) and before the step d ) of discharge of the second mixture (7); in this step a shaping mixture is applied, which comprises unhardened binder (or resin), on the walls of the cavities (5) in the layer of the first mixture (3). The binder or mixture of binders containing this mixture may be the same as or different from the binder or binders used in the first (3) and second (7) mixtures. According to a particular embodiment, the profiling mixture may contain only organic resin or organic resins. According to another embodiment, it may additionally contain a dye or pigment or mixture of dyes and / or pigments; this pigment, dye or mixtures thereof can be the same as the dye used in one of the two mixtures, first (3) or second mixture (7), or be different. Preferably it is a dark pigment or dye. This profiler mix achieves an even greater definition of the vein in the artificial stone, since once applied, it serves as the layer of separation between the first mixture (3) and the second mixture (7) during the filling of the cavities (5) . In the case of a dark pigment, the wide-vein effect generated will be even more realistic, that is, more similar to the appearance of veins in natural stones. The profiler mixture may also contain inorganic particles of small size, for example of the micronized type of quartz or silica, or other additives such as catalysts, adhesion promoters, etc. The profiling mixture is applied or projected onto the surface of the walls of the cavities (5) obtained in the layer of the first mixture (3). The profiler mixture, for example, can be projected by means of a spray head located at the end of a robotic arm, which moves along the cavities (5).
[0149]
[0150] Surprisingly, in addition to the aesthetic effects, by the realization of this shaping mixture, after the hardening of the applied binder mixture, the shaping mixture improves the definition of the streaks and reinforces the mechanical strength of the bond between the substrate mixture ( or first mixture (3)) and the filling mixture (second mixture (7)), reducing the brittleness of the artificial stones obtained at the interface between the two mixtures. As indicated above, the profiling step can be carried out after filling the gaps (23) of the template (2) and removing it, but before filling with the second mixture (7) the cavities (5). ) left by the template (2) in the first mixture (3), or after filling the gaps (23) of the template (2) and pre-compacting the first mixture (3) with the compactor (4), but before filling with the second mixture (7) the cavities (5) left by the template (2) in the first mixture (3).
[0151]
[0152] The islands (22) of the template (2) will have a length, a width and a height. These islands (22), according to a particular embodiment, and as shown in figures 1-5, will be configured, at least partially, with a shape that prevents the first mixture (3) from accumulating on them during the discharge in stage b). There are different possible ways to get to this configuration.
[0153] Thus, according to particular embodiments, the islands (22) of the template (2) are configured, at least partially, in their upper part (which receives the discharge of first mixture (3)) in the form of a ridge or have a superior protection in the shape of a crest. This realization is precisely that shown in Figures 1-5. In this way, the first mixed material (3) discharged slides along the sides of the ridge and falls into the holes (23) of the template (2), without being retained on the islands (22).
[0154]
[0155] Alternatively or additionally, the walls of the islands (22) may be, at least in part, configured with an inclined (not vertical) shape, so that the islands (22) have a greater width in the part closest to the surface (1) than in the upper part of the template (2). In this way the discharged material slides down that slope and / or crest towards the holes (23), and does not remain accumulated on the islands (22) (or branches).
[0156]
[0157] The resulting layer of the combination of the first (3) and second (7) mixtures is then subjected to step e), where it is compacted. Different forms of compaction are possible. Preferably, this compaction is performed through a press, and more preferably in combination with vibration, through the process known as vibro-compression. Additionally or alternatively to the vibrocompression, the compaction can be done with extraction of the air contained in the layer, by means of vacuum application. Vacuum vibro-compaction, suitable for the present invention, is a method widely known in the art and frequently used for the manufacture of articles of agglomerated materials of inorganic or ceramic particles. In this process of vacuum vibro-compaction, the layer resulting from the combination of the first (3) and second (7) mixtures is introduced into a sealed chamber formed by the punch and the surface of a press. During pressing, the sealed chamber is evacuated while vibrating devices subject the mixture to an intense vibration.
[0158]
[0159] After the compaction, the binder hardens in the compacted layer. For this, in the cases in which the binder is an organic resin, this layer is introduced in a furnace at a sufficiently high temperature to produce its curing in a reasonable time. For the catalyzed organic resins of unsaturated polyester, usually used, the temperature will be in the range 80 - 110 ° C and the residence times will be between 15 - 60 minutes. For inorganic binders, of the hydraulic cement type, it is also envisaged that the curing can be carried out at room temperature for a period of one to several days.
[0160] The boards, slabs or plates obtained can be cut and / or calibrated to the desired final dimensions, and can be polished on one or both larger sides, depending on the application that is wanted to be given.
[0161]
[0162] The present invention also relates to any board, slab or sheet obtained by the above-detailed process, and to its use as a construction or decoration material.
[0163]
[0164] According to additional aspects, the present description also refers to a method of manufacturing boards, slabs or plates of artificial stone with vein effect, preferably wide veins, which comprises the following stages:
[0165]
[0166] a) on a surface (1) a template (2) is positioned, which comprises hollows (23) and islands (22), preferably irregular, which correspond to at least one grain of the article to be manufactured;
[0167] b) a first mixture (3), which comprises inorganic particles and a non-hardened binder, is discharged onto the template (2), by means of a first distributing device, so that said first mixture (3) rests on the surface (1) ) and fill in the gaps (23) of the template (2);
[0168] c) the template (2) is removed, obtaining a layer of the first mixture (3) with cavities (5) in said layer, defined by the positions of the islands (22) of the template (2);
[0169] d) a second mixture (7), which comprises inorganic particles and an unhardened binder, is discharged, to fill with said second mixture (7) at least part of the cavities (5) in the first mixture layer (3);
[0170] e) the layer resulting from the combination of first (3) and second (7) mixtures is compacted, preferably by vibration and / or compression and / or vacuum, and a hardening process is carried out, to obtain the board, slab or artificial stone plate with wide grain effect;
[0171]
[0172] characterized in that it additionally comprises one or both of the following steps:
[0173]
[0174] b1) pre-compacted stage, after step c) of download and before step d) of withdrawal of the template (2), in which the content of the gaps (23) left by the template is compacted ( 2) by means of a compactor (4), which preferably comprises a plate complementary to the template (2), which presses the layer of the first mixture (3) against the surface (1); I
[0175] c1) profiling step, after step d) of removing the template (2) and before step e) of unloading the second mixture (7), in which applies a shaping mixture comprising unhardened binder, on the walls of the cavities (5) in the layer of the first mixture (3).
[0176] For steps a), b), b1), c), c1), d), and e), in particular steps b1) and c1), all the characteristics, definitions and particular or preferred embodiments described above in the present description.
[0177]
[0178] According to another additional aspect, the present description also refers to a method of manufacturing boards, slabs or plates of artificial stone with broad veining effect, which comprises the following steps:
[0179]
[0180] a) a template (2) is positioned on a surface (1), template (2) comprising hollows (23) and islands (22), preferably irregular, which correspond to at least one grain of the article to be manufactured;
[0181] b) a first mixture (3), which comprises inorganic particles and a non-hardened binder, is discharged onto the template (2), by means of a first distributing device, so that said first mixture (3) rests on the surface (1) ) and fill in the gaps (23) of the template (2);
[0182] c) the template (2) is removed, obtaining a layer of the first mixture (3) with cavities (5) in said layer, defined by the positions of the islands (22) of the template (2);
[0183] d) a second mixture (7), which comprises inorganic particles and an unhardened binder, is discharged, to fill with said second mixture (7) at least part of the cavities (5) in the first mixture layer (3);
[0184] e) the layer resulting from the combination of first (3) and second (7) mixtures is compacted, preferably by vibration and / or compression and / or vacuum, and a hardening process is carried out, to obtain the board, slab or artificial stone plate with wide grain effect;
[0185]
[0186] characterized in that the islands (22) are, at least in part, configured with a shape that prevents the first mixture (3) from accumulating on them during discharge in stage b). Preferably, the islands (22) will be configured in their upper part with a ridge shape or an inclined shape, so that the islands (22) have a greater width in the part closer to the surface (1) than in the part top of the template (2).
[0187]
[0188] For steps a), b), c), d), and e) all the features, definitions and particular or preferred embodiments described above in the present description are applicable. It is further possible to carry out one or both of the steps b1) and c1) referred to above. All the characteristics, definitions and realizations Particular or preferred embodiments described above in the present description for said steps b1) and c1) are also applicable here.
[0189]
[0190] The present invention also refers to any board, slab or sheet obtained by any of the methods described in the present description, in any of the described modalities, and its use as a construction or decoration material.
[0191]
[0192] According to another additional aspect, the present invention relates to a system or device suitable for manufacturing a board, slab or plate of artificial stone with broad streaks effect, which it fills, with a mixture of filler which may comprise inorganic particles and binder not hardened, irregular cavities, present in a first layer of substrate, system comprising a distributor device mounted on a robotic device, characterized in that the distributor device comprises:
[0193]
[0194] i. a hopper (8) for storing the filling mixture (7), which has an upper opening (81) and a lower opening (82),
[0195] ii. a conveyor belt (9) located under the lower opening (82) of the hopper (8), and
[0196] iii. a manifold (6), with an upper opening (61) and another lower one (62), which collects the filling mixture (7) discharged from the conveyor belt (9) and deposits it in the cavities (5) to be filled substrate (3), preferably having the lower opening (62), in at least one direction, a width (d) less than or equal to the maximum width of the cavities (5) to be filled.
[0197]
[0198] The system or device encompassed by the scope of the invention is particularly suitable in cases where the filling mixture (7) comprises at least 50%, or at least 65%, or in the range of 70-95% by weight of the total mixture of inorganic particles with a granulometry greater than 0.75 mm
[0199]
[0200] According to a particular embodiment, the distributing device and the robotic device are linked, preferably by means of a computer system.
[0201]
[0202] Preferably, said computer system serves to control the amount of filling mixture (7) deposited in the different regions of cavities (5), depending on the width in those different regions of the cavities (5) to be filled.
[0203]
[0204] The system of the invention allows the use of filler blends (5) with inorganic particles and non-hardened binder, where those particles have a large particle size (ie greater than 0.75 mm), mixtures having high tackiness and a great tendency to form aggregates and to clump together. The discharge of the filling material can be controlled and is produced in a homogeneous way, without causing blockages or irregular discharges.
[0205]
[0206] This system or device is also capable of locally unloading a mixture of filler (7) over cavities (5) in the layer of a substrate (3), directly inside the cavities (5), without loss of material and only contamination of the parts of the substrate (3), being able to obtain, in the resulting artificial stone, a greater definition of the veins.
[0207]
[0208] The dispensing device mounted on a robotic device can be moved, thanks to the robotic device, selectively along the cavities (5) of the substrate (3), and discharges different quantities of the filling mixture (5) (for example from particles). inorganic and non-hardened binder) in different regions of the cavities (5), according to the width and shape of said cavities (5). The different quantities discharged from the filling mixture (7) are controlled by means of the material discharge speed of the distributing device in the respective area of the cavities (5) that is being filled, or by the speed of displacement of the material. robotic device, depending on the respective zone of the cavities (5) that is being filled. The robotic device can be an anthropomorphic robotic arm or a Cartesian coordinate robot, and be programmed to selectively follow the irregular and apparently random shapes of the cavities (5) in the substrate layer (3), positioning the distributing device so to discharge the filling mixture (7) mostly into the cavities (5).
[0209]
[0210] According to a preferred embodiment of the invention, the cavity filling system (5) is designed and adapted to discharge different amounts of the filling mixture (7) (for example of inorganic particles and non-hardened binder) in different regions of the cavities (5). While the robotic device moves the dispensing device along the cavities (5), the dispensing device discharges different quantities of filler mixture (7) in different regions of the cavities (5). In other words, the amount of filler mixture (7) discharged can be adjusted to the volume to be filled that the cavity (5) has in the specific region being filled, where the robotic device positions the dispensing device. Preferably, there is a link between the robotic device and the distributor device, which allows synchronization between them, so that the quantity discharged from the filling mixture (7) on the cavities (5) varies according to the position of the robotic device, depending on the width of the cavity (5) in said position. This link and synchronization can be done through a computer system, and the instructions can be given through programming.
[0211]
[0212] The conveyor belt (9) for the filling mixture (7) (for example, inorganic particles and non-hardened binder) of the second distributor device, located above the collector (6) and below the hopper (8), can be example, an "endless" belt, which travels on a closed path on the outside of two or more cylinders, having for example a path through the upper part and return through the lower part. 7) is deposited on the belt (9), and moves simultaneously with this, and upon reaching the part where the belt rotates to return, is discharged through the upper opening (61) of the collector (6), which directs the filling mixture (7) towards the cavities (5) through its lower opening (62).
[0213]
[0214] In a particular embodiment, the speed of the conveyor belt (9) of the second distributor device is kept constant, thereby producing a discharge velocity of the filling mixture (7) (inorganic particles and unhardened binder) constant, while the speed of movement of the robotic device is varied along the cavities (5), producing variations in the amount discharged in different regions of the cavities (5): smaller amount where the movement of the robotic device is faster, and more where the movement is slower Alternatively, the speed of movement of the robotic device can be maintained constant along the cavities (5), while the speed of the conveyor belt (9) is varied along the displacement over the different regions of the cavities (5) . In this case, the discharged amount of filler mixture (7) (inorganic particles and non-hardened binder) in a region of the cavities (5) will be greater, the higher the speed of the conveyor belt (9).
[0215]
[0216] The speed of the conveyor belt (9) of the second distributing device, the speed of the robotic device, and the position of the robotic device are preferably controlled and / or synchronized by a computer processing system, and the instructions preferably given through programming.
[0217]
[0218] This device or system comprising a conveyor belt (9) in the second distributor device eliminates the limitations of other known material design systems (see, for example, EP3095768A1), as to the required fluidity of the mixture used for filling . Asl, when the second device distributor is based on the use of a conveyor belt (9), can be used, as a mixture of filler (7), mixtures composed of aggregates of uncured resin, liquid, with an inorganic filler with high content, for example more than 50 % by weight, or more than 60% by weight, or between 70-95% by weight on the total mixture, of particles of granulometry> 0.75 mm; In this way, these problematic mixtures can be used to fill homogenously, controlled and reproducibly, the gaps that define wide veins, without problems that the distributor becomes clogged or the mixtures can not be projected, as is the case, for example , of the system described in EP3095768A1 for the obtaining of fine veins in artificial stone.
[0219]
[0220] In anticipated embodiments of the invention, it is envisaged that the robotic device carries the second dispensing device to a recharging position, where the discharged amount of filler mixture (7) (inorganic particles and non-hardened binder) is replenished in the hopper ( 8) from the corresponding mixer, mix that is transported by a tape. The device or system, according to another particular embodiment, compatible with the previous embodiments, comprises a hopper level sensor (8), which indicates when it is necessary for the dispensing device to proceed to the recharging position.

权利要求:
Claims (15)
[1]
1. Method of manufacture of boards, slabs or plates of artificial stone with vein effect, which comprises the following stages:
a) on a surface (1) a template (2) is positioned, which comprises recesses (23) and islands (22), where the islands (22) correspond to at least one vein of the article to be manufactured;
b) a first mixture (3), which comprises inorganic particles and a non-hardened binder, is discharged onto the template (2), by means of a first distributing device, so that said first mixture (3) rests on the surface (1) ) and fill at least part of the gaps (23) of the template (2); c) the template (2) is removed, obtaining a layer of the first mixture (3) with cavities (5) in said layer, defined by the positions of the islands (22) of the template (2);
d) a second mixture (7), which comprises inorganic particles and an unhardened binder, is discharged, to fill with said second mixture (7) at least part of the cavities (5) in the first mixture layer (3);
e) the layer resulting from the combination of first and second mixtures is compacted, and a hardening process is carried out, to obtain the board, slab or artificial stone plate with veining effect;
characterized in that in step d) said second mixture (7) is discharged in a localized manner over the cavities (5) in the layer of the first mixture (3), by means of a second distributor device, which comprises a manifold (6), whose lower opening (62) has, in at least one direction, a width (d) less than or equal to the maximum width of the cavities (5), said second device moving along at least part of the cavities (5) , at least partially filling said cavities (5) with the second mixture (7).
[2]
Method of manufacture according to claim 1, characterized in that the second distributor device discharges different quantities of the second mixture (7) in different regions of the cavities (5).
[3]
Method of manufacture according to any of the preceding claims, characterized in that the second distributor device is mounted on a robotic device that moves it along at least part of the cavities (5).
[4]
Method of manufacture according to claim 3, characterized in that the quantities of second mixture (7) discharged by the second distributor device in different regions of the cavities (5) is controlled by means of the rate of discharge of the material by the second distributor device or the speed of movement of the robotic device.
[5]
Method of manufacture according to any of the preceding claims, characterized in that the second distributor device comprises a conveyor belt (9) for the second mixture (7).
[6]
Method of manufacture according to any of the preceding claims, characterized in that the second mixture (7) comprises at least 50% by weight of the total mixture of inorganic particles with a granulometry greater than 0.75 mm.
[7]
Method of manufacture according to any one of the preceding claims, characterized in that, after step b) of unloading and before step c) of removing the template (2), a pre-stage b1) is carried out. -compacted, in which the first mixture (3) discharged in the holes (23) included in the template (2) is compacted.
[8]
Method of manufacture according to claim 7, characterized in that the pre-compaction is carried out by means of a compactor (4), which comprises a plate complementary to the template (2) that presses the layer of the first mixture (3) in the holes (23) of the template (2) against the surface (1).
[9]
Method of manufacture according to any one of the preceding claims, characterized in that, after step c) of removing the template (2) and before step d) of discharging the second mixture (7), it is a shaping step c1) is carried out, in which a roll forming mix comprising binder is applied hardened, and optionally a pigment, on the walls of the cavities (5) in the layer of the first mixture (3).
[10]
Method of manufacture according to any one of the preceding claims, characterized in that the islands (22) of the template (2) are configured, in their part receiving the discharge of first mixture (3), with a shape that prevents the first mixture (3) is accumulated on them during the discharge in stage b).
[11]
11. A board, slab or plate of artificial stone with vein effect, characterized in that it has been obtained by the method of any one of claims 1 to 10.
[12]
12. Use of the board, slab or artificial stone with veining effect according to claim 11, as a construction or decoration material.
[13]
13. A system for manufacturing a board, slab or plate of artificial stone with vein effect, particularly wide veins, which fills, with a mixture of filler, irregular cavities present in a first layer of substrate, system comprising a distributor device mounted on a robotic device, characterized in that the distributing device comprises:
i. a hopper (8) for storing the filling mixture (7), which has an upper opening (81) and a lower opening (82),
ii. a conveyor belt (9) located under the lower opening (82) of the hopper (8), and
iii. a manifold (6), with an upper opening (61) and a lower one (62), which collects the filling mixture (7) discharged from the conveyor belt (9) and deposits it in the cavities (5) to be filled with the substrate (3).
[14]
The system according to claim 13, characterized in that the lower opening (62) of the collector (6) has a width (d) less or equal, in at least one direction, than the maximum width of the cavities (5) to be filled .
[15]
System according to any of claims 13-14, characterized in that the distributor device and the robotic device are linked by a computer system.

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同族专利:

公开号 | 公开日

ES2713776B2|2019-12-19|

EP3713729A1|2020-09-30|

ES2713776B4|2021-06-21|

US20210229313A1|2021-07-29|

WO2019101823A1|2019-05-31|

CN111655438A|2020-09-11|

IL274815D0|2020-07-30|

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优先权:

申请号 | 申请日 | 专利标题

ES201731349A|ES2713776B2|2017-11-22|2017-11-22|METHOD AND SYSTEM OF PRODUCTION OF BOARDS, Slabs OR PLANKS OF ARTIFICIAL STONE WITH EFFECT OF WIDE VETAS|ES201731349A| ES2713776B2|2017-11-22|2017-11-22|METHOD AND SYSTEM OF PRODUCTION OF BOARDS, Slabs OR PLANKS OF ARTIFICIAL STONE WITH EFFECT OF WIDE VETAS|

PCT/EP2018/082136| WO2019101823A1|2017-11-22|2018-11-21|Method and system for producing slabs, tiles or sheets of artificial stone with a wide vein effect|

US16/766,528| US20210229313A1|2017-11-22|2018-11-21|Method and System for Producing Slabs, Tiles or Sheets of Artificial Stone with a Wide Vein Effect|

EP18807324.1A| EP3713729A1|2017-11-22|2018-11-21|Method and system for producing slabs, tiles or sheets of artificial stone with a wide vein effect|

CN201880084659.6A| CN111655438A|2017-11-22|2018-11-21|Method and system for producing slabs, tiles or sheets of artificial stone with a wide-grain effect|

IL274815A| IL274815D0|2017-11-22|2020-05-20|Method and system for producing slabs, tiles or sheets of artificial stone with a wide vein effect|

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