CN101486217B - Method for synthesizing stone by layered vibration and moulding vibration device - Google Patents
Method for synthesizing stone by layered vibration and moulding vibration device Download PDFInfo
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- CN101486217B CN101486217B CN2009100738109A CN200910073810A CN101486217B CN 101486217 B CN101486217 B CN 101486217B CN 2009100738109 A CN2009100738109 A CN 2009100738109A CN 200910073810 A CN200910073810 A CN 200910073810A CN 101486217 B CN101486217 B CN 101486217B
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- 238000000465 moulding Methods 0.000 title claims abstract description 52
- 239000004575 stone Substances 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 24
- 230000002194 synthesizing effect Effects 0.000 title claims description 15
- 239000000463 material Substances 0.000 claims abstract description 82
- 239000002969 artificial stone Substances 0.000 claims abstract description 23
- 239000002245 particle Substances 0.000 claims abstract description 20
- 239000004579 marble Substances 0.000 claims description 16
- 239000000853 adhesive Substances 0.000 claims description 14
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- 235000013339 cereals Nutrition 0.000 claims description 4
- 239000010977 jade Substances 0.000 claims description 4
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 2
- 239000010931 gold Substances 0.000 claims description 2
- 229910052737 gold Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 11
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Abstract
The invention belongs to the field of artificial synthetic stone for building materials, and in particular relates to a method for producing synthetic stone by layered vibration and a molding vibration device for solving the problems of the prior artificial synthetic stone production process and equipment. The method comprises the following synthetic steps: firstly, a base material and an ingredient are alternately distributed in a mold box layer by layer, the ingredient is paved on the base material, and the base material and the ingredient vibrate under vacuum pumping to complete a first layer; secondly, a second layer is machined according to the first step, and the first step is repeated continuously to complete the molding of quarry stone; and finally, the machining process is completed by sawing, grinding and cutting. The device comprises a base plate, an upright post and a supporting frame; the upper part of the supporting frame is provided with a vibrating table; a buffering spring is arranged between the vibrating table and the soleplate; the upper part of the vibrating table is provided with a mold box; the lower part of the vibrating table is provided with a vibrator; the periphery of the supporting frame is provided with an oil cylinder; the bottom end of a piston of the oil cylinder is hung with a vacuum cover; and a vacuum pump is arranged on the vacuum cover. The process is advanced; the particle diameter of the raw material is not limited; a product has high-grade texture and artistic quality; and the device has a simple structure and low construction cost.
Description
Technical field
The invention belongs to the artificial synthetic stone field of construction material, be specially a kind of method and moulding vibration device of synthesizing stone by layered vibration.
Background technology
Along with the progressively raising of people's living standard, synthesis stone is feeded as a kind of novel building, the color and luster that it is beautiful, and novel pattern, elegant decorative effect more and more is subjected to people's favor, and various synthesis stones arise at the historic moment.
Be commonly called as synthetic stone at present into hilllock stone, be to be primary raw material with marble building stones, Paris white and unsaturated-resin after pulverizing, technology through stirring, whole cloth, the system of taking out vacuum, vibration and compression forming, make three-dimensional famine material body, make the building decorative plates that is used for ground and metope through the operation of normal temperature curing, gang saw sawing, grinding again.Oscillator with configurable number platform hydraulic motor transmission in the pressing element of the vacuum forming equipment of existing process matching, and drive its lifting and approach the compacting of 800KN with cylinder, with the disposable moulding of finishing waste material body of vacuum, vibration and three kinds of active forces of compression, this equipment not only will dispose air pressure and two systems of oil pressure, and its seal cavity of tens of cubic metres need be taken out the system vacuum with the vavuum pump of larger capacity, make the entire equipment cost extremely expensive, the equipment use and maintenance cost is high.
Vacuum vibration (shaking by force), compression moulding (suppressing) technology and supporting equipment are adopted in the production of the synthetic stone of existing waste material type, though though the synthetic stone product of making has higher density, but make the building stones consumption that synthesizes greater particle size in the stone raw material be restricted, can not suppress the product of the close combination of big particle diameter building stones with ornamental value, destroyed ornamental value, the synthetic stone of being produced does not thus possess high-grade texture and artistry yet, and surperficial pattern is wayward, and production cost is also very high simultaneously; And need a large amount of mylar as adhesive, and mylar not only costs an arm and a leg (1.5 ten thousand yuan/ton of existing market valencys), and a large amount of uses can make synthetic stone decorative material discharge pernicious gas, do not reach the environmental friendly indoor standard.For example be called on the market in the synthetic stone product of Da Hua, particle diameter is that the building stones consumption of 3.5～12cm can only be below 40%, makes its pattern that forms in the stirring of globality and vibration compacting not break away from the category of color concrete.In addition, angle from the mineral resources utilization, current only have a few marbles such as Song Xiang Yellow and Snow Flower White as the synthetic stone raw material that is commonly called as to hilllock stone, other non-metallic ore, remaining fritter building stones in ore extraction such as granite, jade, perlite and olivine for example, also can't still go out of use mostly, can't rationally utilize as the raw material of synthetic stone.
In addition, artificial quartz in lump adopts quartz sand and unsaturated polyester resin, and the hard product of producing with pressing-plate method presented Market Situation preferably, but existing technology can only be carried out its sheet forming less than the granule building stones of 0.8cm with particle diameter.Entity plane materiel uses the amount of resin more than 20% to make its material body have flowability, only adopt vacuum just can make its material body suspension and sedimentation and moulding, but its product wearability problem relatively poor and that resin demand is too high makes its market prospects pessimistic.
Summary of the invention
The present invention for solve existing artificial stone adopt wholely stir cloth, vacuumize, vibration, compression moulding technology, exist the consumption of big particle diameter building stones in the raw material to be restricted, can't produce synthetic stone product with high-grade texture and art combination, and problem such as supporting former complex structure, use and maintenance cost height, a kind of method and moulding vibration device of synthesizing stone by layered vibration are provided.
The present invention adopts following technical scheme to realize: the method for synthesizing stone by layered vibration, be that in the nonmetallic ore stone granulate of 0.5-20cm any one or a few is as base-material with particle diameter, to comprise the unsaturated polyester resin adhesive, the thick material that stone grain and stone flour mix is as batching, the ratio of weight and number of base-material and batching is 1-6: 1, concrete synthesis step comprises: base-material and batching are alternately carried out cloth successively in the moulding box of moulding vibration device, and batching is laid in the base-material upper surface, under taking out system, vacuum vibrates again, finish first level, on the ground floor basis, carry out the operation of second level then according to above-mentioned steps, so constantly repeat, finish the famine material moulding of producing synthetic stone, at last through sawing, grind and cut and finish its process.Nonmetallic ore stone granulate of the present invention can be marble, granite and other nonmetallic ore, as jade, olivine, garnet, Yuhuatai colorful pebble, perlite and obsidian etc., selecting for use and arranging in pairs or groups of these nonmetallic ore stone granulates can be definite according to people's hobby and aesthetic conceptions, but must guarantee that the ore soft durometer of using simultaneously will be quite, this is a common practise; The main component of the unsaturated polyester resin adhesive in the described batching is made up of unsaturated polyester resin, curing agent, promoter, pigment etc., and described stone flour can be calcareous fine powder of carbonic acid or quartziferous fine powder at least; In the synthesis step, the volume of waste material body can be determined according to the size and actual requirement of moulding box after the cloth number of plies of described base-material and batching and the moulding, the sheet material processing technology that comprises sawing, grinds and cut after the moulding of described waste material is the same with prior art, is well known to those of ordinary skill in the art.
In order further to optimize the synthetic method of synthetic stone of the present invention, in the described batching, the consumption of unsaturated polyester resin adhesive accounts for the 6%-18% of batching gross weight, to be this application people obtain through test of many times and summary of experience for this, if the consumption of adhesive is excessive, can make the material body have very big flowability, and the feature of environmental protection is relatively poor, and the manufacturing cost of product is improved; If the adhesive consumption is less, bonding force is not strong, and leakiness is filled in the base-material gap simultaneously, forms the cavity in the forming process easily, and reduces the crooked equal strength of synthetic stone; When the thickness of each layer base-material and batching reaches 10-25cm, begin to carry out vacuum system of taking out and vibration, so can guarantee that thick batching takes out the bottom that is deep into each level under the effect of system power in vacuum, make and prepare burden and the closely knit combination of base-material that also artistry arrangement and the layering spray decorative pattern for base-material provides advantageous conditions; Above-mentioned synthesis step also comprises base-material shaping and the base-material arrangement base collection operation before the cloth, the base-material shaping is exactly that the non-metallic ore that will select for use grinds off corner angle, be processed into approximate square body or cobble body or Else Rule shape, and base-material arrange to build the collection operation be big or small ore particles is spatially arranged tightr and smooth, the more important thing is and to prepare combination pattern, make it have more artistry and harmonious property, extension or upgrading that these two operations are traditional stone handicrafts; After above-mentioned synthesis step also comprises successively cloth, carry out vaporific dyeing (promptly spraying pigment), make whole sectional drawing line close with natural stone at the batching laminar surface; Described unsaturated polyester resin adhesive can replace with white cement, and the consumption of white cement is 2-5 a times of unsaturated polyester resin adhesive consumption, can obtain the synthetic stone of inorganic artificial; Described base-material by marble particle and expanded perlite with 6: the weight ratio of 1-6 is formed, and the prescription of this base-material can be used for producing artificial hole stone.
Finish the used moulding vibration device of method of above-mentioned synthesizing stone by layered vibration, comprise base plate, be fixed on base plate column all around and the support frame of fixing with each column upper end; The base plate top is provided with shake table, is provided with buffer spring between shake table and the base plate, and shake table top activity is provided with moulding box, and the below is lifted with vibrator; Around the support frame oil cylinder is installed respectively, the piston end activity of oil cylinder is hung with the vacuum cover that cooperatively interacts with moulding box, and the vavuum pump that is communicated with moulding box is housed on the vacuum cover.This moulding vibration device is a kind of have vacuum and equipment that vibrates two big functions and simplify greatly, with the supporting use of above-mentioned synthetic stone production method, greatly reduces production cost, and can satisfy the requirement of synthetic stone production technology fully.Behind the layer-by-layer distribution, send into shake table and fall vacuum cover in moulding box when base-material and batching, start vavuum pump and vibrator, begin to vacuumize, and under the effect of vibrator and buffer spring, the moulding box that is positioned on the shake table begins vibration.
Moulding mechanism of the present invention is: glutinous shape that will stir or thick paste batching, be laid in to arrange and build the good block base-material surface of collection, take out in the vacuum that moulding vibration device provided under the effect of system power and exciting force, batching is filled between the space to base-material, and take out in vacuum under the effect of system power and get rid of bubble, the filling of the batching of grume between the base-material slit utilized the mechanical force of moulding vibration device and the deadweight of base-material piece, and the chemical polycondensation power of utilization batching, under the compacting utensil that the mylar consumption is also little and cancellation is complicated of integral body, finish the high density moulding of mutual perforation, and cloth successively, the layering moulding is key point of the present invention place, every layer thickness just can make its vacuum take out system power at 10-25cm and be deep into its bottom, and also artistry arrangement and the layering spray decorative pattern for base-material provides advantageous conditions.In sum, the present invention utilizes base-material shaping, batching to stir, base-material is built collection, batching is filled, spray pigment, the vacuum system of taking out and seven operations of bottom vibration and constantly circulation repeat many levels, be generally the 2-12 level, finish the famine material polymerization forming that it is carried out persistently, technological process as shown in Figure 1.
Compared with prior art, the present invention adopts distributing mode successively with base-material and batching, under vacuum, successively vibrate and make waste material body with shake table, only carry out moulding with the vacuum system of taking out and bottom two kinds of active forces of vibration, the production method of this layered vibration provides application approach for numerous non-metallic particles such as the granite that self has ornamental value and wearability and jades, and granular size is unrestricted, and building two operations of collection by base-material shaping and base-material can make this method possess the condition of high-grade texture of preparation and artistry processing, and final products have higher density, all indexs all meet the requirements, have synthetic stone product up-gradation and sharp useless social effect, simultaneously the mylar consumption is less relatively, environmental protection and reduced production cost; Only use the simple and easy shaped device of formations such as vacuum cover and moulding box and shake table, simple in structure, easy to operate, the more existing device of its cost can reduce more than 80%, and its lower equipment depreciation expense, lower power consumption and Master Cost further reduce its production cost.In a word, the present invention adopts the ore of the U.S. that self has color and keeps one setting body or machine-shaping body, synthetic stone product so that its natural beauty and combination art are made has the multiple meaning that its former and technological change are regenerated and generation is worth than big market.
Description of drawings
Fig. 1 is the moulding process flow chart of synthesizing stone by layered vibration of the present invention
Fig. 2 is the shaped device structural representation of synthesizing stone by layered vibration of the present invention
Among the figure: 1-base plate 2-column 3-support frame 4-shake table 5-buffer spring 6-moulding box 7-vibrator 8-oil cylinder 9-vacuum cover 10-vavuum pump 11-annular sealing strip
The specific embodiment
Embodiment 1:
The employing pattern is that the marble of market popularity is a base-material, and the unsaturated polyester resin adhesive with 12%, snow white stone grain and stone flour are the raw material of batching; With the moulding box of 305cm (length) * 85cm (wide) * 150cm (height), carry out the texture of spray successively of 6 levels (6 circulations) and successively vibrate and vacuumize, finish the moulding of waste material, the prescription of its base-material and batching is:
1, base-material brocatel (cobble shape) 4-20cm
Brocatel 0.5-3cm
2, white marble 4 meshes of batching
White marble 20 meshes
White marble 80 meshes
Paris white 1000 meshes
The consumption of unsaturated polyester resin adhesive accounts for 12% of batching gross weight, and the ratio of weight and number of above-mentioned base-material and batching is 6: 1,
Concrete synthesis step is as follows: the base-material shaping: adopting appearance similar is abrasive material in the fragment of the cylinder of ball mill, built-in frosted and bistrique, to particle diameter is that brocatel piece more than the 4cm carries out round as a ball processing, makes it grind off corner angle and forms similar and body river (goose) cobble; Batching stirs: composition adding biaxial rneader that will above-mentioned various batchings is with the maximum speed of 20r/min and produce the pyrogenicity process of temperature more than 30 ℃, can be divided into stirring into stickiness 1-6 time and more significantly expecting body; Base-material is arranged and built collection: send the base-material of 1/6 total amount to moulding box with transport tape, available first lay bulk repaves the order of spilling fritter evenly and entirely arranges its ground floor base-material, and preparation color decorative pattern; Batching is filled and is sprayed color: above the cobble body, with spraying the pigment utensil in company with the transmission of expecting body and be distributed in two places and spray dyeing simultaneously, make the sectional drawing line and the base-material of its batching close therebetween the batching lay of 1/6 weight; Vacuum system of taking out and bottom vibration: when the thickness of each layer base-material and batching reaches 10cm, fall vacuum cover to approach-vacuum of 0.1MPa takes out system, and the Vibration on Start-up device carries out the dither of about 100HZ of moulding box and material body with 20-100 time second, finishes the operation of first level; Rise vacuum cover and shake table after the release vacuum, moulding box sends back the cloth district, and base-material stack, the batching of carrying out second level filled, sprays pigment, taken out the operation of making vacuum and bottom vibration.So repeat to finish for six times that it is highly body formed for the famine material of 125cm, after the curing, the saw blade that adopts the following width of 2mm is to its sawing, grinding and the vertical thin plate that can be used for metope and ground decoration that cuts into.
Finish the used moulding vibration device of method of above-mentioned synthesizing stone by layered vibration, as shown in Figure 2, comprise base plate 1, be fixed on base plate 1 column 2 all around and the support frame of fixing with each column upper end 3; Base plate 1 top is provided with shake table 4, is provided with buffer spring 5 between shake table 4 and the base plate 1, and shake table 4 top activities are provided with moulding box 6, and the below is lifted with vibrator 7; Oil cylinder 8 is installed respectively around the support frame 3, the piston end activity of oil cylinder 8 is hung with the vacuum cover 9 that cooperatively interacts with moulding box 6, the vavuum pump 10 that is communicated with moulding box 6 is housed on the vacuum cover 9,4 vibrators of moulding vibration device are divided into 2 groups and coaxial connection respectively, can produce the synthetic excited frequency of 50-150HZ and the exciting rate of 100-600KN in its reverse running.
Embodiment 2:
To adopt expanded perlite and marble building stones be base-material, prepare burden to stir with 18% unsaturated polyester resin and marble stone grain and calcium carbonate stone powder and make, in moulding box, carry out the texture of spray successively of 8 levels (8 circulations) and successively vibrate and vacuumize, finish the moulding of waste material, the prescription of its base-material and batching is:
1, base-material: light marble particle diameter 0.5-2cm
Expanded perlite particle diameter 0.5-2cm
2, white marble 20 orders of batching
White marble 40 orders
White marble 80 orders
Paris white 800 orders
The consumption of unsaturated polyester resin adhesive accounts for 18% of batching gross weight, and the ratio of weight and number of above-mentioned base-material and batching is 2: 1, and marble particle and expanded perlite are with 6 in the base-material: the weight ratio of 1-6 is formed,
Concrete synthesis step is as follows: batching stirs: stir in composition adding biaxial rneader that will above-mentioned various batchings or the cylinder rotary agitator, can be divided into and stir into vicidity 1-8 time and more significantly expect body; Base-material is built collection: send the base-material of 1/8 total amount to moulding box synchronously with batching with transport tape, and preparation color decorative pattern; Spray color:, make whole sectional drawing line close with natural cavity stone with spraying the pigment utensil in company with the transmission of expecting body and be distributed in two places and spray dyeing simultaneously; Vacuum system of taking out and bottom vibration: when the thickness of each layer base-material and batching reaches 25cm, fall vacuum cover to approach-vacuum of 0.05MPa takes out system, and the Vibration on Start-up device carries out the dither of about 150HZ of moulding box and material body with 20-100 time second, finishes the ground floor operation; Rise vacuum cover and shake table after the release vacuum, moulding box sends back the cloth district, carries out the base-material of second level and the lay of preparing burden, sprays pigment, takes out the operation of making vacuum and bottom vibration.So repeat to finish for eight times that it is highly body formed for the famine material of 165cm, after the curing, adopt the saw blade sawing, grind and cut into the synthetic hole stone thin plate that can be used for wall decoration.
Used moulding vibration device such as embodiment 1.
Embodiment 3:
The prescription of base-material and batching is:
1, base-material: Galaxy Black particle diameter 5-15cm
Gold dream granite particle diameter 5-15cm
Jade particle diameter 0.5-2cm
Obsidian particle diameter 0.5-2cm
2, batching
Quartz sand 40 orders
Quartz sand 80 orders
Silica flour 400 orders
The consumption of unsaturated polyester resin adhesive accounts for 6% of batching gross weight, and the ratio of weight and number of above-mentioned base-material and batching is 1: 1,
Concrete synthesis step is as follows: the base-material shaping: the characteristics that the granite fragment utilizes its fragility and homogeneous to be easy to be shaped, be processed into approximate square body with hammer, engraving tool; Batching stirs: will stir in the composition adding biaxial rneader of above-mentioned various batchings, and can be divided into and stir into stickiness 1-10 time and more significantly expect body; Base-material is built and collected: put assembly closely with special-purpose framed 1/10 base-material is built, this special use is framed to be made of the frame all around and the nylon mesh of bottom, hangs successively in moulding box again; Batching is filled and is sprayed color: above square body, with spraying the pigment utensil in company with the transmission of expecting body and be distributed in two places and spray dyeing simultaneously, make whole sectional drawing line close with natural stone therebetween the batching lay of 1/10 weight; Vacuum system of taking out and bottom vibration: when the thickness of each layer base-material and batching reaches 15cm, fall vacuum cover to approach-vacuum of 0.095MPa takes out system, and the Vibration on Start-up device carries out the dither of about 50HZ of moulding box and material body with 20-100 time second, finishes the ground floor operation; Rise vacuum cover and shake table after the release vacuum, base-material stack, the batching of carrying out second level filled, sprays pigment, taken out the operation of making vacuum and bottom vibration.So repeat to finish for ten times that it is highly body formed for the famine material of 125cm, after the curing, adopt the saw blade sawing, grind and cut into the hard sheet that can be used for metope and ground, table top decoration.
Used moulding vibration device such as embodiment 1.
Claims (6)
1. the method for a synthesizing stone by layered vibration, it is characterized in that: be the marble of 0.5-20cm with particle diameter, expanded perlite, Galaxy Black, gold dream granite, in jade and the obsidian particle any one or a few is as base-material, to comprise the unsaturated polyester resin adhesive, the thick material that stone grain and stone flour mix is as batching, the ratio of weight and number of base-material and batching is 1-6: 1, concrete synthesis step comprises: base-material and batching are alternately carried out cloth successively in the moulding box of moulding vibration device, and batching is laid in the base-material upper surface, under taking out system, vacuum vibrates again, finish first level, on the ground floor basis, carry out the operation of second level then according to above-mentioned steps, so constantly repeat, finish the famine material moulding of producing synthetic stone, at last through sawing, grind and cut and finish its process.
2. the method for synthesizing stone by layered vibration according to claim 1 is characterized in that: in the batching, the consumption of unsaturated polyester resin adhesive accounts for the 6%-18% of batching gross weight.
3. the method for synthesizing stone by layered vibration according to claim 1 and 2 is characterized in that: when the thickness of each layer base-material and batching reaches 10-25cm, begin to carry out vacuum system of taking out and vibration.
4. the method for synthesizing stone by layered vibration according to claim 1 and 2 is characterized in that: above-mentioned synthesis step comprises also that base-material shaping before the cloth and base-material are arranged and builds the collection operation.
5. the method for synthesizing stone by layered vibration according to claim 1 and 2 is characterized in that: above-mentioned synthesis step carries out vaporific dyeing at the batching laminar surface after also comprising successively cloth.
6. the method for synthesizing stone by layered vibration according to claim 1 and 2 is characterized in that: described base-material by marble particle and expanded perlite with 6: the weight ratio of 1-6 is formed.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11845198B2 (en) | 2015-01-30 | 2023-12-19 | Cambria Company Llc | Processed slabs, and systems and methods related thereto |
| US11845235B2 (en) | 2014-08-19 | 2023-12-19 | Cambria Company Llc | Synthetic molded slabs, and systems and methods related thereto |
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| CN101486217A (en) | 2009-07-22 |
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