CN111558980B - 合成模制板坯和与其相关的系统和方法 - Google Patents
合成模制板坯和与其相关的系统和方法 Download PDFInfo
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
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- Toxicology (AREA)
- Inorganic Chemistry (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Revetment (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
Abstract
本文描述了用于形成适于起居或工作空间(例如,沿着台面、桌面、地板等)的改进的合成模制板坯的系统和工艺。不同于从采石场取得的毛石板坯,各合成模制板坯可被制造成具有彼此相似的外观,这些外观是可重复的并预定为制造工艺的一部分。然而,在那些实施例中,每个合成模制板坯的外观还可提供复杂的条纹或其它脉纹图案。
Description
本申请是申请日为2015年8月18日、申请号为201580056591.7(国际申请号为PCT/US2015/045693)、发明创造名称为“合成模制板坯和与其相关的系统和方法”的专利申请的分案申请。
技术领域
本文描述了用于形成合成模制板坯产品的系统和工艺,合成模制板坯产品例如是利用包括微粒矿物材料、树脂粘结剂和颜料的混合物通过热成形或以其它方式压实为选定板坯形状的合成模制板坯,该合成模制板坯使得合成模制板坯适用于生活或工作空间(例如,沿着台面、桌面、地板等)。
背景技术
毛石板坯是常用的建筑材料。花岗石、大理石、皂石和其它毛石由于其美观特性而常常被选择用作台面。尽管毛石具有视觉吸引力,但获得这种毛石板坯可能相当昂贵并且它们通常限于天然的配色方案。
工程石板坯可以由材料的人造组合形成,与毛石板坯相比,材料的人造组合能提供改进的抗污或耐热特性。工程石通常是微粒矿物材料和诸如聚合物树脂或水泥之类的粘结剂的组合。某些工程石板坯,特别是那些板坯尺寸较大并且具有粒状外观的工程石板坯明显还达不到毛石板坯复杂的外观和纹理。
发明内容
本文描述的某些实施例包括用于形成适用于起居或工作空间(例如,沿着台面、桌面、地板等)的改进的合成模制板坯的系统或工艺。在特定实施例中,合成模制板坯能被制造成具有彼此相似的外观,不同于从采石场得到的毛石板坯,这些合成模制板坯的外观通常是可重复的并且预定为制造工艺的一部分。然而,在那些实施例中,每个合成模制板坯的外观可以提供模仿毛石板坯的复杂条纹或其它脉纹图案。例如,每个板坯能由不同地着色的微粒矿物混合物的组合形成,不同地着色的微粒矿物混合物根据预定图案竖直地分配到竖直定向的模具内(从而便于形成选定的条纹或其它脉纹图案),模具然后转至水平定向的位置以用于后续压缩模制和凝固操作。如本文所用的,“不同地着色”表示具有不同颜料组合或者以其它方式在色调或视觉纹理方面具有不同视觉外观。
本文所描述的特定实施例包括合成模制板坯,合成模制板坯包括石英材料。可选地,合成模制板坯可以具有至少2英尺宽×至少6英尺长并且垂直于板坯厚度延伸的主表面。主表面可以具有至少一第一着色的脉纹,第一着色的脉纹大体上在长度方向上从一边延伸到另一边,第一着色的脉纹分开至少两个其它脉纹,至少两个其它脉纹大体上在长度方向上延伸并且定位于第一着色的脉纹的相对边缘上。第一着色的脉纹可选地具有等于并且平行于板坯厚度的脉纹厚度。
本文所描述的某些实施例包括一组单独地模制的合成板坯。该组中的每个相应板坯可包括根据对于所有单独模制的合成板坯而言预定图案分布于系列连续层中的至少四种不同微粒矿物混合物。四种不同微粒矿物混合物各自可选地包括石英材料、一种或多种颜料和一种或多种树脂粘结剂。在一优选的选项中,每个相应板坯可以是矩形并且可以具有至少2英尺宽和至少6英尺长的主表面。四种不同微粒矿物混合物中的至少一种混合物可以限定在每个相应板坯的大部分长度上延伸的基本上长度方向的脉纹,使得在该组中的每个相应板坯的主表面具有相似地定位和颜色的基本上长度方向的脉纹。
本文所描述的其它实施例包括利用不同微粒矿物混合物来形成合成模制板坯的工艺。该工艺可以包括将板坯模具定位于基本上竖直定向。该工艺还可以包括将多种不同微粒矿物混合物分配到基本上竖直定向的模具内以便填充模具空间。可选地,模具空间为至少6英尺长×至少2英尺宽,并且多种不同的微粒矿物混合物各自主要包括石英材料。该工艺还可以包括:在不同微粒矿物混合物定位于模具中时,调整模具至基本上水平定向。而且,该工艺可以包括:在模具处于基本上水平定向时,同时振动和压实布置于模具中的微粒矿物混合物。
形成合成模制板坯的工艺的某些实施例包括根据预定图案将多种不同地着色的微粒石英混合物倾倒至非水平定向的模具内。可选地,非水平定向的模具限定内部空间,该内部空间的第一边缘厚度小于并且平行于第二边缘厚度,第二边缘厚度靠近模具的朝向上的开口。该工艺还可以包括在模具处于水平定向时,压实布置于模具中的多种不同地着色的微粒石英混合物。
本文所描述的附加实施例包括一种使用不同微粒矿物混合物的组合来形成合成模制板坯的系统。该系统可以包括模具调整设备,模具调整设备被配置成将板坯模具从基本上竖直定向重新定位成基本上水平定向。可选地,板坯模具可限定模具空间,模具空间为至少6英尺长×至少2英尺宽。该系统还可包括一个或多个矿物集料分布器,各矿物集料分布器被配置成将对应的微粒矿物混合物竖直地分配到由模具调整设备保持的板坯模具内。
本文所描述的系统和技术可以提供以下优点中的一种或多种优点。首先,一种系统可以用来生产多个合成模制板坯,每个合成模制板坯具有相似脉纹图案并且适用于起居或工作空间(例如,沿着台面、桌面、地板等)。这种板坯可以由不同地着色的微粒矿物混合物的组合形成,不同地着色的微粒矿物混合物根据预定并且可重复的分配图案竖直地沉积到竖直定向的模具内,从而提供选定的脉纹图案,该脉纹图案模仿毛石板坯并且对于多个单独模制的板坯中的每个板坯通常是可重复的。
其次,在该系统中的每个板坯能通过一系列操作形成,这些操作至少包括压缩模制操作,在压缩模制操作中,在模具以竖直定向被填充之后,容纳微粒矿物混合物的模具以水平定向定位。例如,不同地着色的微粒矿物混合物竖直地倾倒至竖直定向的模具内,竖直定向的模具然后转至水平定向的位置,以用于后续压缩模制操作(例如,振动-压实模制等)和(在某些实施例中)凝固操作。自此,从硬化的板坯移除某些或全部模具,使得至少板坯的主表面被抛光,以提供模仿毛石板坯的复杂条纹和脉纹图案的外观。在某些可选的实施例中,不同于从采石场取得的毛石板坯,每个合成模制板坯的抛光的主表面提供与该组单独模制的板坯中的其它板坯非常类似的外观。此外,能选择颜料和微粒矿物混合物,以提供相比于利用取自采石场的毛石板坯可以得到的改进的颜色组合和视觉效果,并且提供远超过利用取自采石场的毛石板坯可以得到的多种颜色组合选项。
一个或多个实施方式的细节在附图和以下描述中陈述。通过描述和附图以及权利要求,其它特征、目的和优点将变得明显。
附图说明
图1A和图1B是根据某些实施例的合成模制板坯在成形期间和成形之后的透视图。
图2是根据某些实施例的用于形成合成模制板坯产品的示例性系统的简图。
图3是根据其它实施例的用于形成合成模制板坯产品的另一示例性系统的简图。
图4A和图4B是处于水平配置的图2和图3的板坯模具调整设备的透视和剖视图。
图5是图4A和图4B的板坯模具调整设备的另一剖视图。
图6A至图6C是处于竖直配置的图4A和图4B的板坯模具调整设备的透视和剖视图。
图7是由图2和图3的系统中的任一系统形成的示例性合成模制板坯产品的透视图。
图8是用于形成合成模制板坯产品的示例性工艺的流程图。
具体实施方式
参考图1A和图1B,可使用一种系统来生产具有根据预定图案的多个条纹或脉纹的一种或多种合成模制板坯50。每个板坯50可以包括石英材料和/或其它微粒矿物材料,石英材料和/或其它微粒矿物材料当与颜料和树脂粘结剂混合并且随后被压缩和凝固时提供适用于起居或工作空间(例如,沿着台面、桌面、地板等)的硬化板坯产品。如图1A至图1B所示,每个板坯50可能可选地由不同地着色的微粒矿物混合物的组合形成,不同地着色的微粒矿物混合物根据预定并且可重复的分配图案被竖直地倾倒入竖直定向的模具130(参考图2)内,竖直定向的模具130对于每个单独模制的板坯提供通常是可重复的选定的条纹或其它脉纹图案。板坯模具竖直定向并且从开口端被填充。不同微粒矿物混合物(例如,不同颜料、不同矿物组合物、不同添加剂等)的连续层根据预定并且可重复的分配图案竖直倾倒至模具内直到完成填充。使开口端闭合,并将模具130枢转到水平定向(参考图2至图3中的设备150)且以水平定向运输,用于压实、凝固和其它操作。如图1B所示,取决于不同微粒混合物的预定分配图案,竖直分配/分层工艺可以提供模仿诸如花岗石或大理石之类的毛石板坯的脉纹外观的分层效果,包括完全在硬化板坯50(例如,至少2英尺宽×至少6英尺长,以及宽在约3英尺至5英尺之间且长在约6英尺至14英尺之间,优选地约4.5英尺宽(更特别地,约140cm宽)×约10英尺长(更特别地,约310cm长))的整个长度L上延伸的某些脉纹51、52、53和54。其它脉纹55可仅部分地在板坯50的长度L上延伸。这种不同地着色的脉纹51、52、53、54不仅能在板坯产品的整个长度上延伸,而且这种脉纹51、52、53和54(以及部分脉纹55)也能穿过板坯50厚度延伸(从而即使板坯被切割并且切边成起居或工作空间中(例如,沿着台面、桌面、地板等)的具体形状,也提供自然脉纹外观)。因为在该组单独模制的板坯中的每个板坯50可以包括根据预定并且可重复的分配图案竖直地分配到模具130(参考图2)内的不同微粒矿物混合物层,故而在该组单独模制的板坯中的多个板坯50可以具有彼此基本上相同的外观。
现更详细地参考图1A至图1B和图2,在将不同微粒矿物混合物分配到模具130内期间,模具130可以竖直地定向。例如,如在下文中更详细地描述的,模具130可以包括壳体部分,壳体部分至少部分地限定一空间(在图1A中以虚线示出),该空间用于经由模具130的朝向上打开的开口132接收不同的微粒矿物混合物。可选地,每种不同的微粒矿物混合物从单独输送线(参看图2至图3)分配,输送线将相应混合物运输到朝向上的开口132上方的区域,使得相应混合物然后被竖直地倾倒至模具130内。每个输送线可根据预定图案来运输相应混合物使得不同微粒混合物向模具内倾倒预定系列连续层,其中的某些或全部能形成板坯50的脉纹51、52、53、54、55。可选地,不同微粒矿物混合物的连续层中每一个可以以不同量分配,从而提供不同尺寸和位置的脉纹或条纹。而且,每个单独层可在模具130的一端具有与模具130的另一端处不同的尺寸,从而进一步改善在硬化板坯50中的复杂条纹和脉纹图案,以便更多地模仿毛石板坯(例如,传统毛花岗石板坯等)。
在此实施例中,板坯50包括单独地输送并且分配到竖直定向的模具130的朝向上的开口132内的四种不同微粒矿物混合物。不同的混合物可以在模具(在下文中更详细地描述)被压实模制并且凝固以便提供复合石材的硬化板坯50(图1B)。用来形成复合石材料的混合物的一种或多种混合物可以包括(多种)有机聚合物和无机(矿物)微粒组分。无机(矿物)微粒组分可包括诸如下列组分:硅、玄武石、玻璃、金刚石、岩石、鹅卵石、贝壳、多种含石英的材料或者其任何组合,含石英的材料诸如但不限于:碎石英、砂、石英颗粒等。在此实施例中,所有四种不同的微粒矿物混合物各包括石英材料作为主要组分,石英材料可包括各种粒度和不同组合的砂。在硬化板坯50(图1B)中,能使用粘结剂来联结有机和无机材料,粘结剂包括例如:单官能或多官能硅烷分子、树枝状分子等,粘结剂可能能够粘结复合石混合物的有机和无机组分。粘结剂还可包括各种组分的混合物,各种组分诸如是:引发剂、硬化剂、催化剂、粘结分子和桥或者其任何组合。在模具130(图1A)中分配的某些或全部混合物可包括在被输送到模具130之前在混合设备(图1A中未示出)中组合的组分。混合设备可以用来以各种比例掺混原料(诸如石英材料、有机聚合物、不饱和聚合物等)。例如,在模具130中分配的某些或全部混合物可包括约8-95%石英集料和约5-15%聚合物树脂。此外,可以将各种添加剂添加到混合设备中的原料中,这些添加剂可包括金属片(例如,铜微粒等)、着色剂、染料、颜料、化学试剂、抑菌物质、杀菌剂等或其任何组合。在替代实施例中,(上述)石英集料的某些量或所有量可以被瓷料和/或陶瓷集料材料替换或者包括瓷料和/或陶瓷集料材料。
仍参考图1A至图1B和图2,模具130可以在分配矿物微粒混合物期间竖直定向,由此模具的主表面定位于竖直位置或大体上竖直位置(例如,相对于水平为90度±10度)。在这些情形下,每种矿物微粒混合物竖直倾倒至模具内并且搁置于矿物微粒混合物的先前沉积的层上(其中,第一层则沉积到竖直定向的模具130的闭合底边缘上)。优选地,模具130至少部分地限定硬化板坯50的长度L和宽度W(因为在后续压实和凝固的整个工艺中,模具130将微粒矿物混合物保持在其中)。在某些实施例中,形成于模具130中的板坯50的宽度W为至少2英尺,在约3英尺至5英尺之间且优选地为约4.5英尺,并且形成于模具130中的板坯50的长度L为至少6英尺,在约6英尺至15英尺之间且优选地为约10英尺。因此,例如板坯50可以具有4.5英尺的宽度W和10英尺的长度L。替代地,板坯50可以具有26英寸的宽度W和10英寸的长度L。也可以由此设想到在上述范围内描述的其它板坯尺寸。照此,即使每个板坯50可以具有相当大的长度L,脉纹51、52、53和54中的某些或全部也可以在板坯50的整个长度上延伸。此外,脉纹51、52、53和54中某些并不在板坯50的整个长度上延伸,至少那些不在板坯50的整个长度上延伸的脉纹中的某些能可选地基本上在板坯50的整个长度上延伸,使得在最初的观察中,观察板坯的人最初看到脉纹的分离的部分连接形成完整长度的脉纹。可选地,在将矿物微粒混合物竖直分配到模具130内期间,模具130的下边缘处的厚度T1可以不同于在其上开口132处的厚度T2。例如,厚度T2可以为厚度T1的约两倍。可以使用不同的厚度T1和T2而导致:随着将微粒矿物混合物的附加层沉积到模具130内,在板坯的下边缘附近发生的微粒矿物混合物的额外压实。在模具130旋转到水平定向以用于后续板坯50的压实和凝固之后,混合物被更均匀地压实在一起并且模具130限定板坯50的总体连续厚度T(图1B)。在某些实施例中,形成于模具130中的板坯50的厚度T为至少0.2cm、在0.2cm至5cm之间,并且优选地为约3cm。每个模具130可以由包括柔性聚合物(包括弹性体材料)、纸、木材、金属或其组合的结构形成。
现参考图2,在某些实施例中,用来形成一组合成模制板坯产品(例如,图1B中的板坯50、图7中的板坯600等)的系统100被配置成将不同地着色的微粒矿物混合物竖直倾倒至竖直定向的模具内,竖直定向的模具然后转成水平定向位置,以用于后续压缩模制操作(例如,振动压实模制、凝固等)。在所描绘的实施例中的系统100包括输入输送机110和输出输送机120。一批板坯模具130在输入输送机110上运输。板坯模具130提供了用于本文所描绘的某些实施例中至少三英尺宽且至少六英尺长、约4.5英尺宽×约10英尺长的合成模制板坯产品的形状。输入输送机110将板坯模具130运输到模具定位台140,模具定位台140被配置成帮助操作者移动和/或定向板坯模具130。
在此实施例中,板坯模具130水平移动(例如,相对于重力)到设备150上,设备150用来使每个模具130在竖直定向与水平定向之间枢转。在此实施例中,该设备150用作倾翻台150,其被配置成接纳板坯模具130中的一个或多个,固定板坯模具130,并且使板坯模具130从水平定向枢转至(上述)竖直定向,其中,当处于竖直定向时,开口边缘(在图1A中的附图标记132)定位于板坯模具130的顶部上。例如,在此实施例中,倾翻台150被配置成一次接纳并且可释放地保持一个模具130。进一步关于图4A至图6C描述倾翻台150的此特定实施例的附加细节。在替代实施例中,倾翻台150可以被配置成一次接纳并且可释放地保持多个模具130。
仍参考图2,在此实施例中,在设备150中竖直定向的模具130被配置成接纳四种不同地着色的矿物混合物(如上述主要包括石英材料),这四种不同地着色的矿物混合物能从四个对应的混合器输送并且引导至输入装置160,输入装置160诸如是分配器头或其它材料运输结构。在此实施例中,每个分配器头160被配置成释放与其它分配器头160相比不同的微粒矿物混合物(例如,不同颜料、不同矿物组合物、不同添加剂或其组合)。每个分配器头160被配置成可控制地分配其用于输入到由倾翻台150保持的竖直定向的模具130内的对应微粒矿物混合物的供应。例如,分配头160可以各自被配置成具有挡板或阀设备(未图示),挡板或阀设备可被控制以调节从分配头160输入装置到模具130内的微粒矿物混合物流量。在这些实施例中,分配头(或者用于将微粒矿物混合物分布到模具130内的其它输入装置)可以根据预定控制算法被控制,以便限定用于竖直地分配到由倾翻台150保持的板坯模具130内的不同地着色的微粒矿物混合物的连续层。
当倾翻台150将模具130保持在竖直定向时,模具130的朝向上的开口132(图1A)定位于矿物集料分布器160的输出装置(例如,相对于重力的)下方。因此,微粒矿物混合物从分布器160的输出装置分配并且然后通过模具130的朝向上的开口132(图1A)。因此,分布器160(每个分布器160根据其对应分配头要分配的图案运送不同的微粒矿物混合物)可以用来将相应混合物倾倒至竖直定向的模具130内以提供(对于流水线中的每个模具130而言是可重复的)预定系列的连续层。如前所述,不同微粒矿物混合物的这些连续层中的某些或全部可以形成硬化板坯(例如,图1B中的板坯50、图7中的板坯600等)的长度方向的脉纹。
在图示示例中,使用四个矿物集料输入装置160,但是在其它示例中,板坯可以由1种至20种之间不同的微粒矿物混合物并且更优选地由3种至8种之间不同的微粒矿物混合物形成(在某些实施例中将提供包括对应数量的输入装置160的系统)。在某些示例中,矿物集料分布器160的数量可以等量地对应于用来产生硬化板坯产品的不同地着色的微粒矿物混合物的数量。
在由倾翻台150保持的板坯模具130(在处于竖直定向的定向时)已被充分填充后,倾翻台150枢转或者以其它方式将板坯模具130调整到水平定向。板坯模具130(现为已填充的模具180)在由另一模具定位台170提供的空气垫上从倾翻台150移到输出输送机120。如图2所示,竖直地分配到模具130内的不同微粒矿物混合物的连续层在已填充的模具180内总体是明显的且以水平定向布置于输出输送机120上。不同微粒矿物混合物的这些连续层中的某些或全部可以形成硬化板坯(例如,图1B中的板坯50、图7中的板坯600等)的长度方向的脉纹。
可选地,该系统100可以被配置成提供一个(与当模具130处于倾翻台150上时由先前倾倒至模具130内的不同微粒矿物混合物的连续层限定的大体上“长度方向”的脉纹51、52、53和54(图1B)相比)大体上更“宽度方向”或横向的脉纹192。可选地,这些宽度方向的脉纹192可以比由不同微粒矿物混合物的连续层限定的大体上“长度方向”的脉纹更薄并且分布得更开。而且,这些宽度方向的脉纹192可以由具有不同于从输入装置160分配的微粒矿物混合物的着色的材料形成。例如,该系统可以被配置成对于每个模具而言,将用于宽度方向的脉纹192的微粒矿物混合物可控制地分配到选定位置或分配成选定的图案,之后模具前移到顶部模具附连操作194或振动压实压机195(图2),从而提供对于每个已填充的模具而言可重复的宽度方向的脉纹192的预定图案。在某些可选的情形下,宽度方向的脉纹192可能并不延伸穿过硬化板坯的整个厚度(这可能不同于大体上长度方向的脉纹51、52、53和54(图1B)中的某些或全部)。
仍参考图2,输出输送机120可以被配置成将每一个已填充的模具180运输到系统100中用来使硬化的板坯成形的一个或多个后续工位。例如,每个已填充的模具180可以继续到后续工位,在后续工位,顶部模具附连件194定位于已填充的模具180上以便在模具130与顶部覆盖模具零件(在图2中未示出)之间包住微粒矿物混合物层。从那里,已填充的模具180(现包括顶部覆盖模具零件)继续到后续工位,在后续工位,振动压实压机195向已填充的模具180内的内含物施加压实压力、振动和真空,从而将微粒混合物转变为刚性板坯。在振动压实操作之后,已填充的模具180(其中具有压实并且硬化的板坯)继续到凝固工位196,在凝固工位196,用来形成板坯的材料(包括任何树脂粘结剂材料)经由加热工艺或其它凝固工艺而凝固,从而进一步增强在已填充的模具180内侧的板坯。在板坯充分凝固之后(并且可选地,在板坯被冷却之后),主要模具130和顶部模具覆盖零件在模具移除工位197处从硬化并且凝固的板坯移除。主要模具130然后返回到输入输送机110(图2)。然后,在某些实施例中,硬化并且凝固的板坯移动到抛光机工位198,在抛光机工位198,板坯的主表面被抛光到一定光洁度,从而使复杂条纹和脉纹图案的外观模仿毛石板坯。替代地,抛光机工位198并未被实施,使得所形成的板坯具有比光滑抛光表面更多纹理的主表面。在系统100的某些实施例中,每个合成模制板坯的抛光或以其它方式暴露的主表面能提供对于其它板坯(来自图2中的其它已填充的模具180)而言基本上可重复的外观。
现参考图3,用来形成合成模制板坯产品的另一示例性系统200可以被配置成同时填充多个竖直定向的模具130,从而在某些情形下提高生产率。系统200的布局和操作与系统100(图2)基本上相似,具有输入输送机110、输出输送机120、模具定位台140和170、板坯模具130和已填充的模具180。然而,系统200包括八个矿物集料输入装置160,其中四个输入装置160被布置成将四种不同微粒矿物混合物馈送至固定到倾翻台150的第一竖直定向的模具130内,并且另一组四个输入装置160被布置成将四种不同微粒矿物混合物馈送至固定到第二倾翻台150(在图3中不可见)的第二竖直定向的模具130内。
因此,系统200的操作基本上类似于系统100(图2)的操作,除了多个模具130基本上竖直定向并且同时被填充,之后被调整为水平定向并且作为已填充的模具180移动到输出输送机120。如图3所示,(在此实施例中,使用两个相邻的倾翻台150)同时被填充的已填充的模具180可以具有由根据预定图案倾倒至每个模具内的不同微粒矿物混合物的连续层限定的基本相同的脉纹外观。
现参考图4A和图4B,在系统100或200中的每个倾翻台150可以被配置成接纳处于水平定向的模具130。倾翻台150相对于重力竖直地定位于填充斜槽301下方。在系统100和200(分别地,图2和图3)中,斜槽301在带164的端部处位于(多个)间隙166的竖直下方,以例如从矿物集料分布器160至板坯模具130内引导填充。倾翻台150包括由枢转点306a和枢转点306b(看不到)连接的一组支承件302的集合和台基座304。支承件302提供支承以将台基座304从地板抬高,并且枢转点306a-306b提供轴承,台基座304能通过轴承相对于支承件302倾斜。
如前所述,模具定位台308提供一机构(例如,辊、输送机、致动臂等),用来(例如,在倾翻台处于水平配置时)将板坯模具移动到在台基座304与顶板310之间的倾翻台150内。可选地,薄膜320在顶板310与板坯模具130之间跨顶板310的表面延伸。薄膜320从进给辊322进给并且由卷取辊324收集。在使用中,可选的薄膜在顶板310与沉积到模具内的填料材料之间提供保护屏障(例如,以在重复用于一系列模具130期间维持顶板310的清洁)。薄膜320的预定长度可以一次用于每次模具填充操作,或者依次用于多次模具填充操作,之后前移到卷取辊324,并从进给辊322提供薄膜320的新长度。致动器350的集合可控制地将顶板310与台基座304和板坯模具130分开定位。
图5是图1至图4B的倾翻台150的另一剖视图。在图示视图中,板坯模具130以水平定向定位于倾翻台150内。致动器的集合350被致动以使模具垫片402与板坯模具130的外周缘接触。致动器的集合350被致动以使顶板310朝向板坯模具130移动,从而在板坯模具130与顶板310之间压缩模具垫片402。可选地,模具垫片402与板坯模具130的组合包括呈梯形长方体形式的略微不对称(例如,参考关于图1A所描述的T1和T2)。在图5所示的配置中,板坯模具提供六面梯形长方体形式的三个边缘和一个主面,并且薄膜320和顶板310形成另一主面。板坯模具130的开口端410形成梯形长方体形式的第六面(例如,第四边缘)。在此实施例中,各主面以微小角度定向成为非共面的,其中长方体具有沿着可打开端部410的相对较大的厚度(图1A的T2)和小于沿着可打开端部410的厚度的沿着相对边缘的厚度(图1A的T1)。在倾翻台150处于图5所示的配置的情况下,板坯模具130准备好被重定位于竖直定向用于填充。
现参考图6A至图6C,图1至图5的倾翻台150能通过绕枢转点306a-b枢转而将板坯模具130调整为竖直定向。具体地,通过使台基座304、模具定位台308、顶板310、模具垫片402和薄膜320相对于支承件302在枢转点306a-306b上枢转而将板坯模具130定向至竖直位置。如图6B所示,在图示示例中,板坯模具130部分地被填充不同微粒矿物混合物502的连续层(例如,部分地通过模具填充工艺进行;关于另一示例,另外参考图1A)。如在图2和图3的描述中所论述的,不同的微粒矿物混合物经由输入装置160可控制地释放并且通过开口端410(在此实施例中在重力下)倾倒至斜槽301内,并且进入到板坯模具130内。不同微粒矿物混合物502包括各种设计和选择的混合物(在此实施例中主要包括石英材料),以连续层竖直地倾倒至模具130内,这可产生不同的脉纹层506a-506b。如在先前关于图1A和图1B所描述,脉纹层506a至506b中的某些或全部能基本上从一边到另一边并且在板坯模具130的长度L上延伸。
如前所述,在此实施例中,板坯模具130提供梯形长方体形式。在图示的竖直定向中,板坯模具130的不对称从顶部向底部发生,从而形成非常略微的“V”形(例如,也指关于图1A所描述的T1和T2的描述)。在某些实施例中,不对称可选择为在混合物填充板坯模具130时至少部分地补偿重力对于模具130的下边缘处的不同微粒矿物混合物502的略微压实的效果。可选地,振动器530使板坯模具130和微粒矿物混合物502振动和/或摇晃,从而促进对模具130的完全填充。一旦板坯模具130被根据预定图案来自分布器160(图2和图3)的微粒矿物混合物502充分填充,板坯模具130就变成已填充的模具180(参考图2和图3)。
现参考图6c,示出了斜槽301和板坯模具130的开口端410(也指图1A中的朝向上的开口132)的放大视图。在此实施例中,开口端410包括模具端盖520并且模具端盖520可绕枢转点522运动以可选择地打开和闭合可打开的端部410。当板坯模具130被充分填充填料502时,模具端盖520枢转到闭合位置以提供长方体形状的第六面(例如,以闭合已填充的模具的开口端)。然后倾翻台150将已填充的模具从竖直定向(图6A至图6C)调整为水平定向(参考图4A至图5)。启动致动器350以将已填充的模具180从倾翻台150释放,且已填充的模具180能从倾翻台150移出到输出输送机120(图2和图3)上。
现参考图7,可由图2和图3的系统中的任一个使用根据预定图案竖直地倾倒至模具130内的不同地着色的微粒矿物混合物的组合来形成示例合成模制板坯产品600。在某些实施例中,合成模制板坯产品600可以提供脉纹外观,根据预定的不同微粒混合物的分配图案,脉纹外观模仿诸如花岗石或大理石之类的毛石板坯。例如,板坯600的主表面612可以被抛光,并且提供在硬化板坯600(其可以是约6英尺至约14英尺长,并且在此实施例中优选地约10英尺长)的整个长度上完全延伸的至少某些脉纹602、606和608。其它脉纹605和609可以仅部分地在板坯50的长度上延伸,并且某些脉纹605可以具有小得多的尺寸(但是可能为暗得多的色调)。这种不同地着色的脉纹(例如602、605和605)不仅能在板坯产品的整个长度上延伸,而且这种脉纹也能穿过板坯600的厚度610从第一主面612延伸到相对主面614(从而即使在板坯被切割和切边成起居或工作空间中的具体形状(例如,沿着台面、桌面、地板等)时也提供自然脉纹外观)。此外,至少板坯600的主表面612可以包括多个脉纹607,多个脉纹607相对于脉纹602、605、606、608和609在横向上定向。这种脉纹可以例如由次要分配器190限定(参考图2和图3)。这些“宽度方向”的脉纹607中的某些可以完全在硬化板坯600的整个宽度上延伸(其可以是约2英尺和约6英尺宽,并且在此实施例中优选地约4.5英尺宽)。因为在该组单独模制的板坯中的每个板坯600(例如,参考图2和图3的系统)可以包括根据预定并且可重复的分配图案竖直地分配到模具130内的不同微粒矿物混合物层,故而在该组中的多个板坯600可以具有在主表面中相似定位的脉纹并且可以提供彼此基本上相同的外观。
合成模制板坯600可以被切割、铣削、机械加工或者以其它方式加工成各种形状和尺寸(例如,以提供定制的台面表面,且这些台面表面具有可选的用于水槽、水龙头或其它设施的孔)。例如,从合成模制板坯产品600切下部段630。脉纹602和605延伸到内部606和/或在厚度610上延伸,切割和/或加工合成模制板坯产品600以模仿毛石板坯的美观的方式展示出脉纹602、605、606、608和609。
图8是用于形成合成模制板坯产品(诸如上述板坯50或600)的示例性工艺700的流程图。在某些实施方式中,图2和图3的系统100可以用来执行工艺700。工艺700可以包括操作710:将板坯模具定位于非水平定向,例如基本上竖直定向或横向于水平延伸的另一定向。在这种操作中,模具的主面(其将限定板坯产品的主面)可以例如由倾翻台或另一模具调整设备定位于基本上竖直位置(相对于水平约90度+/-30度(优选地+/-10度))。在上文所描绘的某些实施例中,模具的主面(其将限定板坯产品的主面)能由倾翻台150(图2和图3)定位于竖直定向的位置(相对于水平约90度+/-10度)。该工艺700还可以包括操作720:将多种不同微粒矿物混合物分配到竖直定向的模具内。例如,如前所述,主要包括石英材料的不同地着色的混合物(例如,包括微粒石英材料、一种或多种颜料和一种或多种树脂粘结剂的混合物)可以使用分布器160(图2和图3)之一被馈送至竖直倾倒操作。之后,该工艺700可以包括操作730:在不同微粒矿物混合物定位于模具中时将模具调整到水平位置。同样,这种操作能例如由倾翻台150(图2和图3)或者另一模具调整设备来执行。工艺700还可以包括操作740:在模具处于水平定向时,同时振动并压实布置于模具中的微粒矿物混合物。在这些情形下,操作740可以提供复合石材的压实的板坯。而且,在某些实施例中,工艺700还可以包括操作750:使压实的板坯凝固。工艺700还可以包括操作760:抛光板坯的主表面以在板坯的抛光表面上提供包括但不限于上述示例的脉纹外观。
尽管在上文中详细地描述了多种实施方式,但也能做出其它修改。例如,在附图中描绘的逻辑流程并不要求示出的特定次序或顺序来实现所希望的结果。此外,可以向所描述的流程提供其它步骤,或者可以从所描述的流程消除某些步骤,并且可以向所描述的系统添加其它部件或者从所描述的系统移除其它部件。因此,其它实施方式也在权利要求的范围内。
Claims (16)
1.一种包括石英材料的经加工板坯,包括:
至少2英尺宽乘以至少6英尺长并且垂直于板坯厚度延伸的主表面,所述主表面具有第一弯曲着色的脉纹,所述第一弯曲着色的脉纹大致在长度方向上从边缘延伸到边缘,其中,所述第一弯曲着色的脉纹的脉纹厚度等于且平行于所述板坯厚度,其中,所述板坯包括多种不同的微粒矿物混合物,所述微粒矿物混合物按照预定图案分布在一系列连续层中,所述多种不同的微粒矿物混合物中的第一微粒矿物混合物限定了所述第一弯曲着色的脉纹,并且其中,所述第一微粒矿物混合物在限定所述第一弯曲着色的脉纹的第一区域处占据整个板坯厚度,并且所述多种不同的微粒矿物混合物中的第二微粒矿物混合物在第二区域处占据整个板坯厚度;
还包括横向于所述第一弯曲着色的脉纹延伸并与之相交的多个横向着色的脉纹,所述横向着色的脉纹并不延伸穿过所述板坯的整个厚度;
其中,所述第一弯曲着色的脉纹分离大致在长度方向上延伸的至少第二脉纹和第三脉纹,所述第二脉纹和所述第三脉纹位于所述第一弯曲着色的脉纹的相对边缘上,并且所述第二脉纹和所述第三脉纹各自都是弯曲的脉纹,并且所述第一弯曲着色的脉纹、所述第二脉纹和所述第三脉纹都沿相同的方向弯曲;
其中,所述横向着色的脉纹的材料层叠在大致在长度方向上延伸的脉纹顶部,所述横向着色的脉纹比所述第一弯曲着色的脉纹更细,并且所述横向着色的脉纹通过将所述板坯从竖直定向调整到水平定向且接着将不同着色的微粒分配到所获得的板坯上来形成。
2.根据权利要求1所述的经加工板坯,其特征在于,所述横向着色的脉纹具有与所述第一弯曲着色的脉纹不同的颜色。
3.根据权利要求2所述的经加工板坯,其特征在于,至少一个所述横向着色的脉纹大致在宽度方向上从边缘延伸到边缘。
4.根据权利要求1所述的经加工板坯,其特征在于,所述多种不同的微粒矿物混合物各自包括石英材料、一种或多种颜料和至少一种粘结剂。
5.根据权利要求1所述的经加工板坯,其特征在于,所述多种不同的微粒矿物混合物是多种不同颜色的微粒矿物混合物。
6.根据权利要求5所述的经加工板坯,其特征在于,至少所述多种不同颜色的微粒矿物混合物中的第二微粒矿物混合物限定了所述第二脉纹。
7.根据权利要求6所述的经加工板坯,其特征在于,所述第二脉纹是第二弯曲着色的脉纹。
8.根据权利要求7所述的经加工板坯,其特征在于,所述第一弯曲着色的脉纹和所述第二弯曲着色的脉纹分别包括多于一个弯曲部分,所述弯曲部分在第一方向上朝向所述主表面的第一长边缘而远离所述主表面的相对长边缘弯曲。
9.根据权利要求6所述的经加工板坯,其特征在于,所述第二脉纹和所述第三脉纹大致在长度方向上从所述板坯的边缘延伸到边缘。
10.根据权利要求6所述的经加工板坯,其特征在于,所述板坯的主表面被抛光,并且至少部分地由于所述多种不同颜色的微粒矿物混合物根据预定图案在一系列连续层中分布而模仿毛石板坯的外观。
11.根据权利要求6所述的经加工板坯,其特征在于,所述第一弯曲着色的脉纹、所述第二脉纹和所述第三脉纹在所述经加工板坯的前主表面和后主表面上均可见。
12.成组的单独加工的板坯,所述组中的每个相应板坯包括按照对于所有单独加工的板坯的预定图案在一系列连续层中分布的多种不同的微粒矿物混合物,所述微粒矿物各自均包含石英材料、一种或多种颜料以及一种或多种树脂粘结剂,其中,每个相应板坯具有至少2英尺宽乘以至少6英尺长且垂直于板坯厚度延伸的主表面,所述主表面具有第一弯曲着色的脉纹,所述第一弯曲着色的脉纹大致在长度方向上从边缘延伸到边缘,其中,所述第一弯曲着色的脉纹的脉纹厚度等于且平行于所述板坯厚度,其中,所述板坯包括多种不同的微粒矿物混合物,所述多种不同的微粒矿物混合物按照预定图案分布在一系列连续层中,所述多种不同的微粒矿物混合物中的第一微粒矿物混合物限定了第一弯曲着色的脉纹,并且其中,所述第一微粒矿物混合物在限定所述第一弯曲着色的脉纹的第一区域处占据整个板坯厚度,并且所述多种不同的微粒矿物混合物中的第二微粒矿物混合物在第二区域处占据整个板坯厚度;并且其中,所述组中每个相应板坯的主表面具有类似定位和着色的弯曲着色的脉纹,所述组中的每个相应板坯的所述主表面还包括横向于所述第一弯曲着色的脉纹延伸并与之相交的多个横向着色的脉纹,所述横向着色的脉纹并不延伸穿过所述板坯的整个厚度;相应的所述第一弯曲着色的脉纹分离大致在长度方向上延伸的至少第二脉纹和第三脉纹,所述第二脉纹和所述第三脉纹位于所述第一弯曲着色的脉纹的相对边缘上,并且所述第二脉纹和所述第三脉纹各自都是弯曲的脉纹,并且所述第一弯曲着色的脉纹、所述第二脉纹和所述第三脉纹都沿相同的方向弯曲,其中,所述横向着色的脉纹的材料层叠在大致在长度方向上延伸的脉纹顶部,所述横向着色的脉纹比所述第一弯曲着色的脉纹更细,并且所述横向着色的脉纹通过将所述板坯从竖直定向调整到水平定向且接着将不同着色的微粒分配到所获得的板坯上来形成。
13.根据权利要求12所述的成组的单独加工的板坯,其特征在于,所述多种不同的微粒矿物混合物是根据预定图案分布在一系列连续层中的多种不同颜色的矿物混合物,所述多种不同颜色的微粒矿物混合物中的第一微粒矿物混合物限定了相应的所述第一弯曲着色的脉纹。
14.根据权利要求13所述的成组的单独加工的板坯,其特征在于,至少所述多种不同颜色的微粒矿物混合物中的第二微粒矿物混合物限定了所述第二脉纹。
15.根据权利要求14所述的成组的单独加工的板坯,其特征在于,相应的所述第二脉纹是第二弯曲着色的脉纹。
16.根据权利要求12所述的成组的单独加工的板坯,其特征在于,所述横向着色的脉纹具有与所述第一弯曲着色的脉纹不同的颜色。
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