EP0566084A1 - Process and device for making composite panels with natural stone slab - Google Patents

Abstract

A description is given of a process for producing composite stone slabs which each comprise a carrier layer of concrete and a natural-stone slab (4), the two of which are intimately connected to each other. The proposed mechanical process consists in that the natural-stone slab (4), which has been turned such that its upper side faces downwards, is moved onto a vibrating table and enclosed in a sealing manner by a mould frame (1), in that concrete is then introduced into the mould frame (1) and compacted by vibration, and in that the concrete layer applied in this manner is moulded by raising the mould frame (1). On its inner side, the mould frame (1) has a region (11) which corresponds approximately to the height of the natural-stone slab (4) and is set back. In this region there is arranged a peripheral groove (13) into which there is introduced a flexible hose (7), the internal pressure of which can be controlled. A description is also given of the moulding machine used and the feed and centring of natural-stone slabs (4). <IMAGE>

Description

The invention relates first of all to a process for the production of composite stone slabs, which in their position of use each consist of a lower base layer made of concrete and an upper natural stone slab, the concrete being intimately connected to the natural stone.

Such composite panels are required, for example, where a natural stone floor covering is exposed to particularly high weight loads due to vehicles or for other reasons. The concrete base layer gives the natural stone the required breaking strength and its material value is much cheaper than natural stone.

As far as composite stones of this type have been used so far, they were made entirely by hand. As a result, the saving effect of using the less expensive material concrete was practically negligible. In many cases, the connection between concrete and natural stone was also poor, which should not infrequently be due to inadequate compaction of the concrete.

The invention has for its object to provide a usable mechanical method for producing such composite stones, wherein natural stone slabs with 3 to 5 cm thickness and an area of z. B. 0.5 m² should be assumed. The concrete base layer can be 10 to 15 cm thick.

This object is achieved according to the invention by the method features characterized in claim 1. The natural stone slab is then turned upside down on a vibrating table and then sealed by a mold frame. Concrete is then introduced into the mold frame and compacted by shaking with a stamp. The vibrating forces can be applied in a manner known per se in concrete block molding machines, i. H. by shaking the mold itself, but preferably by vibrating the vibrating table and / or by shaking a stamp load.

It is essential in this process that the natural stone slab is at the bottom because the water content of the concrete migrates downwards when it is shaken and the strength and adhesion of the concrete in the connecting layer is particularly high. The shaping takes place, as is known per se, by raising the mold frame, the stamp initially maintaining its position and thus preventing the concrete layer from being torn off from the natural stone.

If the mold frame initially slides over the natural stone slab to enclose and hold it, it is important to avoid damage to the natural stone slab. Even a slight lateral offset or a twisting of the plate relative to the frame can lead to a hard impact and breakage of the natural stone plate, especially since the mold frames in modern machines go down very quickly. It is therefore proposed that the natural stone slab be precisely and locally aligned with the projection of the mold frame by means of a centering device by moving it on its base before it is received in the mold frame. To do this, the centering device must first be brought up to the natural stone slab. Movable straightening members of the device then move at least two intersecting edges of the natural stone slab against corresponding stop bars. Then the directional organs release the plate again and finally the entire centering device is moved back into a rest position.

Another type of alignment or centering of the natural stone slab on its base can advantageously already take place when it is placed on it, if this is done with the aid of a gripper, in particular a suction head. It is proposed to arrange a funnel-shaped guide shaft, the lower mouth of which corresponds almost exactly to the plate outline and is only slightly higher than the natural stone plate above the bearing surface. The natural stone slab is then lowered on the gripper, which can move freely in the horizontal direction, down through the shaft and aligns itself automatically.

The alignment problem can finally also be solved by the fact that the mold frame can be automatically adjusted to different plate formats, for example with the aid of hydraulic cylinders or the like. Such a form frame is first set to plate oversize and lowered so far that it surrounds the natural stone plate. This enables a desired, relatively large alignment tolerance when depositing the plates. However, if the natural stone slab is caught by the frame, the frame is tightened until its frame parts line up with the side surfaces of the natural stone slab and this is aligned.

Another development of the method is that when the mold frame is lowered onto the aligned natural stone slab and encloses it, a gripping and sealing strip is pressed from the inner wall onto the side surfaces of the natural stone slab, which not only seals but also holds the natural stone slab in place, that it can be raised using the mold frame. Thus, the mold frame itself serves as a conveyor to place it on the vibrating table or a vibrating table support. The vibrating table preferably has a support made of an elastic material in order to protect the sensitive natural stone. A plastic that is commercially available under the trademark Vulkollan (Bayer) is suitable for this. Depending on the type of machine used, a wooden board can also be provided as a vibrating table support, optionally with the interposition of an elastic layer.

The above-mentioned supporting function of the mold frame is also of importance if no boards are provided as production documents and means of transport in the machine type used. In this case, it is proposed that the finished composite panel be raised again after the application of the concrete by means of the mold frame and then placed and shaped on the storage surface from which the natural stone panel had previously been received.

A simple way of practicing the proposed method is to include a molding machine that can be moved on a track to use a vibrating table that can be moved horizontally back and forth in the machine. This type of machine is also used as a multi-layer paver, for example for concrete paving stones. The input of the natural stone slabs and output of the composite slabs can be done by hand. It is proposed that the natural stone slabs in the mold frame corresponding arrangements are designed with equal distances in the track of the mold frame on the floor, that the molding machine moves forward in accordance with these distances and that during each stop on the one hand the natural stone slabs of an arrangement by means of the mold frame are included with provided the concrete layers and placed back on the floor as finished composite panels and that, on the other hand, the natural stone panels of a following arrangement are aligned by means of a centering device on the relevant projection of the mold frame. Certain constructive measures are discussed in more detail.

However, the so-called floor production with a mobile mechanical device described requires long downtimes due to the hardening time required for the concrete to harden. In addition, a lot of space is lost due to the necessary large distances between the plates placed in the production hall. Since the production of the composite panels only takes place in batches, this manufacturing principle is relatively unproductive. In the following, two further process variants are therefore proposed, each with stationary machine devices.

To a certain extent, the following variant represents the kinematic reversal of the floor production. Essentially the same molding machine can be used, also with a vibrating table that can be moved horizontally back and forth. However, this machine is arranged in a stationary manner, namely at a certain height on a pedestal and a horizontal conveyor runs under the machine. This is moving also gradually at equal intervals and promotes the individually designed natural stone slabs. The form frame lifts the natural stone slabs away from the conveyor level on the vibrating table and after the concrete layer has been applied, the composite slab is put back on the conveyor and shaped in the process. The composite panels must then be removed from the horizontal conveyor for further processing and for setting, for which purpose a gripper can preferably be used, which clamps the natural stone panel in question on two opposite side surfaces and can thereby carry it.

The use of a board paver is proposed as the third basic process variant. This is a stationary molding machine with a non-moving vibrating table. The natural stone slabs placed on each of the production boards are guided together with these production boards by means of a horizontal conveyor of the molding machine that moves progressively at equal intervals. The production boards are placed one after the other on the vibrating table. The mold frame lowers over the natural stone slab lying on the board and when the mold is filled, the production board is also shaken. After molding, the composite board remains on the production board and is conveyed along with it.

What is important for this variant of the process is the fact that neither the natural stone slab alone nor the finished composite slab has to be raised during the production of the composite slab. However, due to the presence of the production board, which usually consists of hardwood, the vibration conditions during compression are not always clear and controllable. The boards with the composite panels lying thereon can then be fed to the known conveying, stacking and storing devices.

Another advantageous development of the method variants mentioned is that the stacked natural stone slabs are automatically separated by means of a horizontally and vertically movable suction head and laid out on the horizontal conveyor or the production boards.

Finally, it is proposed that in order to improve the connection of the concrete with the natural stone slab, a concrete strengthener, adhesive or adhesive is applied to the natural stone surface. It is particularly expedient to automatically wash the individually designed natural stone slabs before coating them with concrete on their underside facing upwards and then also to coat them automatically with the relevant adhesive, in particular a concrete adhesive.

In addition to the manufacturing method, the invention also relates to an arrangement for carrying out this method. The formation of the mold frame, which is of crucial importance for the functioning of the mechanical manufacturing process, is to be mentioned here first. It is proposed that the mold frame have sealing and stripping elements on its inside in the thickness range of the natural stone slab. These serve to prevent the concrete slurry from running out over the side surfaces of the natural stone slab and to strip off the side surfaces of the applied concrete layer during molding. Another very important proposal is that the mold frame has a circumferential groove on its inside in the thickness range of the natural stone slab, into which an elastic hose is inserted, the internal pressure of which can be controlled.

The hose is preferably a closed ring, that is, from four miter-cut hose pieces assembled and provided with a connecting line which penetrates the wall of the mold frame on the outer side facing away from the natural stone slab. In the simplest case, a round hose is used, which lies in a cross-sectionally rectangular or square groove. If the hose is pressurized, it swells out over the groove and lies against the side surface of the natural stone slab.

The hose has several different functions. In the first place is the sealing of the mold frame against the natural stone slab, which forms the bottom of a flat box, which holds the concrete to be filled and is intended to prevent concrete sludge from escaping along the sanded side surface of the natural stone slab.

The hose then has a carrying function. Its contact force and friction on the natural stone side surface should be so large that the plate does not slip out due to its weight and inertia forces when lifting the mold frame.

In addition, there is a centering and protective function, although it should also be noted that the lower section of the mold frame has a clear width at least up to a height corresponding to the thickness of the natural stone slab, which is a few millimeters larger on all sides than the width of the natural stone slab. An air gap is therefore provided all around so that the natural stone slab is not damaged by jarring with the mold frame when it is shaken. The hose has the important function of keeping the separation gap equally wide everywhere by applying the same forces from all sides, i.e. centering the plate within the mold frame. This provides protection against damage to the plate.

Apart from this, exact centering is also of the utmost importance to achieve a clean outer contour of the composite panel. The side surfaces of the natural stone slab must lie in one plane with the side surfaces of the concrete support layer. This is also only ensured by the hose, because at the beginning of the manufacturing process it forms the only physical connection between the natural stone slab and the mold frame.

Finally, the hose also serves to smooth the side surface of the concrete layer, in particular at the transition point, when molding. During the shaking, it cannot be avoided that concrete slurry penetrates into the cavity which is present above the hose between it and the shoulder of the mold frame. The mass that has penetrated here is stripped off when the mold frame is pulled up or smeared smoothly by the elastic hose lip.

Basically, you will set the groove in the mold frame as high as possible to keep the cavity mentioned small. On the other hand, the shoulder of the mold frame must be at an appropriate distance from the upper edge of the natural stone slab, which prevents bouncing when shaking. It can also be useful to attach a chamfer to the edge of the natural stone slab, which should run as parallel as possible to the shoulder surface. As a further security when the natural stone slab is initially immersed in the mold frame, this can also be provided with a chamfer on the inside of its lower edge, which widens it in a funnel shape.

It is proposed to control the inner pressure of the hose very carefully and in accordance with the work program. When inserting the natural stone slab into the mold frame, the hose should be depressurized and pulled back into the groove. The highest pressure is required to carry the plate. A medium pressure should be appropriate when shaking.

Possibly a breathing movement of the hose after shaping can contribute to self-cleaning of the aforementioned cavity, which is filled with concrete slurry. Depending on the design of the hose cross section, a negative pressure in which the hose contracts can also be advantageous in certain work phases.

Various variants are proposed for the hose and groove cross section. In order to promote the retraction of the hose in the depressurized state, it is expedient if the groove is narrowed towards the groove openings by bead-like projections of the groove side walls. The groove side walls can also be intentionally kept flat so that the hose, which is also provided with flat flanks, can slide between them. In order to achieve a high contact force, the hose can have a flat pressure surface between the flanks. However, this can also be provided with sealing lips or grooves. In a further development of this idea, it can be expedient to go completely away from the cross section of a hose with an essentially uniform wall thickness and to form a rectangular gripping and sealing strip with a full cross section on the latter. It is also proposed that the hose on the back, i. H. is held in the interior of the groove, so that it completely retracts into the groove due to its elasticity or due to the application of negative pressure. This fixing of the tube in the groove can also be effected by a corresponding design of the cross section, for example in that a bead is formed on the back of the tube, which snaps into a correspondingly designed receiving groove.

In order to prevent damage to the natural stone slab by the aforementioned bump contact between its upper edge and the mold frame, it is also proposed that above the groove containing a hose an elastic groove in a parallel groove on the inside of the mold frame Bumper protection strip is inserted. The arrangement and dimensions of this strip should best be chosen so that its upper edge is higher and its lower edge is lower than the horizontal surface of the natural stone slab.

Finally, it is proposed that a strip is provided between the hose and the natural stone slab side surface, which consists of a different material than the hose and is only actuated by this. You can also separate the gripping and sealing functions and, in addition to the hose, provide your own movable organs for carrying the natural stone slab.

Finally, there are some constructive measures that are useful for the different process variants. One suggestion is to pivotally mount the centering device on the side of the molding machine at which the natural stone slabs enter the molding machine. The centering device is designed as a frame, with two frame legs forming the stop strips and the straightening members being movably, in particular pivotably, mounted on the other frame legs. Of course, it is also possible to accommodate several natural stone slabs in a multi-chamber mold frame and coat them accordingly. In this case, the centering device must have more stop bars and straightening members.

In order to be able to move the machine forward in exactly the same steps in the case of concrete production, it is proposed that index cams are arranged on at least one travel rail, to which the molding machine is positively coupled during its stop. In this way it is possible, despite the considerable size of such a machine, to define the travel path with such a small tolerance that the lowering mold frame without contact and thus without Damage over the natural stone slabs available.

Finally, this special manufacturing process requires that the index cams are arranged at a distance along the track which is equal to the horizontal distance of the centering device from the mold frame or an integral fraction of this distance. Only in this way is it possible to manufacture and center during the holding phase. If the cam distance is equal to the aforementioned fraction, the machine only takes up a centered natural stone slab two or three steps later for production.

Marble, granite or other suitable stones can be considered as natural stone. The visible side can be ground or natural rough, as it results when the stones are split. The side surfaces of the natural stone slabs are very accurate with this method, for. B. sawn or ground with a tolerance of 0.4 mm with respect to the given dimensions, so that the side surface is also at right angles to the plate surface. The surface to be connected to the concrete is left rough.

Fig. 1

einen vertikalen Teilschnitt eines Formrahmens zur Herstellung von Verbundsteinen,

Fig. 2a

das Detail A aus Fig. 1 in größerem Maßstab,

Fig. 2b

in gleicher Darstellung eine andere Variante des Details A aus Fig. 1,

Fig. 3

eine mehrfach geschnittene Draufsicht einer Schlauchdichtung, wie sie bei dem Formrahmen nach Fig. 1 verwendet ist in einem bezüglich Fig. 2 etwas kleineren Maßstab,

Fig. 4 - Fig. 7

verschiedene Varianten von Schlauchquerschnitten im Maßstab wie Fig. 2,

Fig. 8

eine Seitenansicht einer fahrbaren Formmaschine mit ihrem Gleis, vorbereitend ausgelegte Natursteinplatten und fertige Verbundplatten,

Fig. 9

eine Draufsicht der Gesamtanordnung nach Fig. 8,

Fig. 10

ein Querschnitt der Zentriervorrichtung der Formmaschine nach Fig. 8 in größerem Maßstab und

Fig. 11

die Draufsicht der Zentriervorrichtung nach Fig. 10,

Fig. 12

eine Seitenansicht einer stationären Formmaschine mit zugehörigen stationären Komponenten, wobei als Förderer ein Endlos-Kettenförderer ohne mitlaufende Fertigungsbretter vorgesehen ist,

Fig. 13

eine Seitenansicht einer stationären Brettfertigeranlage mit vorgeschalteten zusätzlichen Komponenten,

Fig. 14

eine schematische Draufsicht auf eine weitere Anlage zur automatisierten Herstellung von Mehrschichtplatten,

Fig. 15

eine schematische Seitenansicht eines Ablegewagens der Anlage nach Fig. 14,

Fig. 16

eine schematische Seitenansicht eines Fertigungswagens der Anlage nach Fig. 14, wobei zur besseren Veranschaulichung ein Teil der Seitenwand weggebrochen ist, und

Fig. 17

einen vertikalen Schnitt durch eine gefüllte Kastenform.

An embodiment of the invention is explained below with reference to the drawing. In detail shows

Fig. 1

a partial vertical section of a mold frame for the production of composite blocks,

Fig. 2a

detail A from FIG. 1 on a larger scale,

Fig. 2b

in the same representation another variant of detail A from FIG. 1,

Fig. 3

2 shows a multi-sectional top view of a hose seal, as used in the form frame according to FIG. 1, on a somewhat smaller scale with respect to FIG. 2,

Fig. 4-7

different variants of hose cross sections on a scale like FIG. 2,

Fig. 8

a side view of a mobile molding machine with its track, preparatively designed natural stone slabs and finished composite slabs,

Fig. 9

8 shows a plan view of the overall arrangement according to FIG. 8,

Fig. 10

a cross section of the centering device of the molding machine according to FIG. 8 on a larger scale and

Fig. 11

10 shows the top view of the centering device according to FIG. 10,

Fig. 12

2 shows a side view of a stationary molding machine with associated stationary components, an endless chain conveyor without a moving production board being provided as the conveyor,

Fig. 13

a side view of a stationary board manufacturing plant with upstream additional components,

Fig. 14

1 shows a schematic top view of a further system for the automated production of multilayer boards,

Fig. 15

FIG. 2 shows a schematic side view of a depositing carriage of the system according to FIG. 14,

Fig. 16

14 shows a schematic side view of a production trolley of the system according to FIG. 14, with part of the side wall broken away for better illustration, and

Fig. 17

a vertical section through a filled box shape.

Since two natural stone slabs are treated together in the manufacturing process to be described, the mold frame shown in FIG. 1 has two chambers. It consists of four outer walls 1, a support flange 2 being attached to each of two opposite walls. The chambers are separated from each other by a somewhat thicker partition 3 and each take on a square natural stone slab 4, which are 60 cm wide and 4 cm thick. Fig. 1 shows the situation at the end of the compression phase. On the natural stone slab, the visible side of which is turned downwards, there is an approximately 12 cm thick base layer 5 made of concrete. The stamping plates 6 fitting into the molding chambers, the load of which is not shown, can, as is customary in concrete molding machines, be moved in height independently of the molding frame.

Each natural stone slab 4 is enclosed by a sealing tube 7. In this example, it is a simple, cross-sectionally round tube according to FIG. 4, FIG. 2a showing this tube under high internal pressure, which deforms it accordingly. 3, the hose is composed of four miter cut and vulcanized sections. A connecting hose 8 branches off from the hose ring and is guided on one side facing away from the natural stone plate 4 through one of the outer walls 1 (not shown).

In its upper section, in which the stamp 6 runs and concrete is filled and compacted, the molding chambers have a clear width which corresponds exactly to the width of the natural stone slab 4. Starting a little above the natural stone slab, the molding chamber widens over an inclined shoulder 9 and forms an approximately 2.5 mm wide gap 10 with the side surfaces of the natural stone slab 4. The recessed flat surface section 11 at the lower end of the outer wall 1 goes into an inclined surface 12 below which, in the event of an inaccurate centering of the natural stone slab, is intended to prevent its damage when the mold frame is lowered.

In the area of the recessed surface section 11, the outer wall 1 has an essentially rectangular groove 13, the upper side wall of which is approximately at the same height as the upper surface of the natural stone slab according to FIG. 2. The groove is for opening, i.e. H. narrowed towards the natural stone slab by two bead-like arched projections 14 on the groove side walls. Finally, the natural stone slab 4 has a chamfer 15 on its upper edges.

The natural stone slab 4 is thus on all sides a distance from the outer wall 1, so that it can not be damaged when shaken. The all around uniform width of the gap 10 is also important because the side surfaces of the base layer 5 must form a common plane with the side surfaces of the natural stone slab 4. This is also effected by the hose 7 which can be acted upon by air pressure. It seals the gap 10 all around and presses so firmly on the side surfaces of the natural stone slab 4 that it does not slide down when the mold frame is lifted, not even when concrete is already in the molding chamber is filled and compressed. However, some of the concrete weight is borne by friction on the outer walls of the mold. Ultimately, the rubber hose at Form that the concrete slurry, which penetrated into the recess between the shoulder 9 and the hose 7 during shaking, is pushed up and distributed so that the finished composite panel is presented with smooth side walls. For this purpose, the air pressure in the hose 7 is reduced to such an extent that the hose can fulfill this function of a wiping lip. The complete removal of the air pressure has the consequence that the hose 7 completely returns to the groove 13 due to the beads 14.

2b shows another embodiment of the sealing point on the outer frame wall 1a. The tube groove 13a has a slightly different cross-sectional shape than in the first exemplary embodiment. It is rounded at the bottom of the groove. Another rectangular groove parallel to it is provided above the hose groove, into which a shock protection strip 45 made of rubber or a suitable plastic is inserted. This groove lies at the transition point between the upper section and the lower, recessed section of the inner wall surface. The impact protection strip 45 is set back somewhat further than the upper section and protrudes beyond the lower section. The natural stone slab 4a used here has no bevel on the transition edge between its surface 46 and its side surface. The upper edge of the impact protection strip 45 lies above this surface 46 and the lower edge lies below this surface 46 of the natural stone slab.

5 shows another hose cross section which is intended for a groove with flat side walls and which accordingly has flat flanks 16 and a flat pressure surface 17. Wedge-shaped sealing lips 18 are formed on this in the manner of an adhesive suction cup.

6 differs from the previous one by a smaller oval cavity and by an almost rectangular solid profile section, the can also be referred to as a molded gripping and sealing strip 19.

In addition to a further hose profile, the associated groove shape is also shown in FIG. 7. What is essential here is a rear T-shaped profile projection 20, which engages in a corresponding shape of the groove base and thus holds the otherwise round tube in the groove, which widens towards the groove opening. If the hose is pressurized, it fills the groove and extends beyond it over a relatively large width, which is indicated by dash-dotted lines.

A molding machine 21 is shown schematically in FIGS. 8 and 9, which can move on rails 23 with its wheels 22. The floor surface between the rails is a flat surface, for example a smooth concrete line, and maintains a constant distance from the rail surface. The machine has columnar vertical guides 24, on which a stamp bear 25 and the mold frame 26 shown in FIG. 1 can be moved up and down independently of one another. The mold frame is filled from a storage silo 27 for the concrete mixture used by means of a horizontally movable filling box 28. Horizontal guides 29 make it possible to move a vibrating table from a working position in the area of the vertical guides to the right into a rest position, so that the mold frame 26 and the stamp bear 25 can be moved all the way down, so that the mold frame stands on the floor.

As shown in FIG. 8, in front of the molding machine 21 moving to the right, two natural stone slabs 4 are laid out next to one another at equal distances x between the rails 23. At an equal distance x index cams 30 are attached to a rail, which form-fit with a suitable gripping device on the machine frame fit together and thereby firmly connect the machine moving progressively from one index cam to the other with each stop at the track, so that the step size can be maintained with the highest precision.

The natural stone slabs 4 are deposited by hand and with only imprecise visual aids. A plastic film can be underlaid to protect the ground plate surface. So that the mold frame can grasp the plate pairs precisely, they have to be aligned by machine, for which purpose a centering device 31 is provided in the example. It is articulated on the front of the molding machine so as to be pivotable upwards about a horizontal axis 32. It bears against a stop 33 in the swung-up rest position.

Details of the centering device are shown in FIGS. 10 and 11. A rectangular frame 34 made of U-shaped rails, on which two bearing arms 35 are seated, is approximately the size of two natural stone slabs 4. The frame cross leg facing away from the molding machine 21 carries a stop bar 36 which is at the bottom while on two cross struts is attached to the first vertical stop bar 37 pointing in the direction of travel. On the outside of the other frame legs, bearing eyes 38 are arranged in pairs, which carry swivel frames 39. With their buffers 40 and their pneumatic drive cylinders 41, these swivel frames form the aforementioned straightening members. 10 shows such a straightening member on the left-hand side in the pivoted-out position.

In connection with the described device, the manufacturing process proceeds as follows: The molding machine shown is located at one of the preselectable stops in contact with one of the index cams 30. In this position, two natural stone slabs 4 are located exactly under the molding frame 26. The next two pairs of slabs following are also below the Molding machine and are already centered. The next following pair of plates, on the other hand, is located outside the base of the machine but in the area of influence of the centering device 31.

The form frame moves down and encloses the two natural stone slabs. The two hoses 7 are now pressurized and then the mold frame with the plates moves up. Now the vibrating table is moved to the left and the mold frame lowers on it. The air pressure is briefly reduced so that the natural stone slabs fit the vibrating table level. Now the air pressure in the hoses is increased again, so that the mold frame is sealed and the plates are held in the middle of their mold chambers. Now the mold frame is filled with a concrete mixture by driving over it with the filling box 28 and thereby vibrated in between. Then the stamps are lowered and the final compression is carried out by means of the vibrating table and the vibrators of the stamp load. Then the mold frame lifts a little together with the natural stone slabs, the compacted concrete filling and the stamps, so that the vibrating table can move to the side. Now the aforementioned arrangement moves downwards until the mold frame 26 stands on the floor. This is followed by shaping, for which the air pressure in the tubes 7 is reduced a little and only the molding frame 26 is first raised. The semi-limp hoses smooth the side walls of the concrete base course. Finally, the stamp bear 25 is also taken into the upper rest position.

Centering takes place during or after this molding process, but while the machine frame is still stationary. For this purpose, the centering device 31 is folded down, so that two natural stone slabs are located under the rectangular frame 34 and roughly in the areas between the stop bars 36 and 37 and the straightening members 39, 40. Now the pneumatic drive cylinder 41 actuates the latter, with the result that the buffers 40 move the natural stone slabs and bring them against the stop bars 36 and 37. The plates are now precisely aligned. The straightening organs are withdrawn and the entire centering device is pivoted up into its rest position. Since the pivot axis 32 is higher than the plates, the stop bar 36 immediately moves away from the plates, while the buffers no longer touch the plates when the device is pivoted up.

Now the molding machine advances another step x. The mold frame 26 can now accommodate another centered pair of plates. The finished composite panels 42 remain on the floor behind the molding machine 21. In the example, the longitudinal distance of the mold frame from the centering frame is three times the increment x, so that a certain centered pair of plates is picked up by the mold frame after three forward steps.

The system shown in FIG. 12 contains the same multi-layer paver machine as the molding machine 21a, as is also shown in the example according to FIGS. 8 and 9. However, the molding machine 21a is stationary on approximately 60 cm high column feet 50 and is also arranged in the opposite direction. A horizontal conveyor, consisting of an endless chain 51 guided over two deflecting rollers, not shown, moves under this molding machine. The chain is connected at intervals x supporting plates 52 made of steel in such a way that they can be deflected at the ends with the chain, in the conveying plane however, are guided exactly horizontally, with the aid of support rollers or the like ensuring that the support plates 52 can also be loaded with a sufficiently high weight. The conveyor moves gradually with the interposition of stopping times so that the support plates 52 are always in the same place below the centering device 31, come to a standstill below the mold frame 26, etc. The direction of conveyance runs from left to right according to the arrows indicated.

A molding and coating station 53 is connected upstream of the molding machine 21. It comprises a portal scaffold 54 bridging the conveyor, on the carrier rail extending in the conveying direction a trolley 55 can move. The trolley carries a vertically telescopic suction head 56 and a coating roller 57, which is also attached to a vertically telescopic handle. A stack 58 of delivered natural stone slabs is on a storage table 59. To the right of the centering device 31 is a trough 60 containing concrete adhesive.

A gripper station 61 is also indicated on the outlet side to the right of the molding machine 21a, which serves to laterally remove the finished composite panels from the conveyor and to feed them for further processing and determination. The gripper used here is designed so that it grips the respective natural stone slab of the composite slab on two opposite side surfaces.

The working procedure for this system is as follows: During a downtime, the suction head 56 detects the uppermost natural stone slab of the stack 58. The trolley 55 then moves so far to the right that the suction head can place the detected natural stone slab on the corresponding support plate 52 of the conveyor. During this time, the coating roller 57 picks up concrete glue from the trough 60. Then the trolley 55 again moves a little to the left and the coating roller 57 moves down and carries out the coating process. In the next station, the natural stone slab 4 prepared in this way is aligned by means of the centering device 31. In the next station, the natural stone slab comes to rest under the mold frame 26.

The machine performs its duty cycle as described in the previous embodiment, i. H. the molding frame picks up the natural stone slab and then places the finished composite slab again on the same support plate 52. The composite plate is removed from the conveyor in the gripper station 61. Additional auxiliary stations can be switched on as required. So it is z. B. expedient to wash the surface of the natural stone slab before applying the concrete adhesive. Even after the composite panel has been completed, it may be necessary to automatically clean the side surfaces of the natural stone panel by scraping or washing residues of adhesive.

Finally, Fig. 13 shows a stationary board manufacturing plant. The molding machine 65 of another make shown here differs from the molding machine described so far apart from many different structural details in that a relatively low-lying stationary vibrating table 66 is provided. A board conveyor 67 comprises two horizontally movable rods or chains, on which pusher pawls 68 which are tiltable about horizontal axes are mounted at a distance x. Furthermore, a stationary slide track or roller track is provided, on which the production boards 69 can be pushed further from left to right in the direction of the arrow. The pawls hold the boards on the left edge and dive under the boards when moving back. The boards move gradually to the right. The conveyor automatically takes a board from a board magazine 70 at the beginning of the conveyor line (left). The surface of the vibrating table 66 is approximately at the same height as the conveying plane, so that the boards come to rest on the vibrating table one after the other in the production station.

The molding machine 65 shown comprises a molding frame 71, a stamping bear 72, a vertical guide 73 for these parts and a horizontally movable filling car 74. On the input side of the molding machine there is a lay-up station 75 with a movable suction head 76 and a coating station 77, the coating roller 78 of which is moistened with concrete adhesive from a funnel-shaped storage container 79 which is arranged directly above it and moves with it.

A typical feature of this working method is the fact that the composite panel is manufactured from the start on the associated production board. In the laying station 75, the natural stone slab is placed on a production board 69. In a subsequent station, it is coated with concrete adhesive on the same board and aligned by the centering unit 31. A special feature of this example is that the frame of the centering device covers the side surfaces of the natural stone slab during painting. For this reason, the frame elements are a little higher than the thickness of the natural stone slab. Finally, the production board reaches the vibrating table 66. The mold frame 71 moves down to the support on the production board 69. Then it is filled, vibrated and shaped and finally the finished composite panel leaves the molding machine 71 on its production board to the right. The production boards can then be fed with the products known conveyor and storage facilities. After the concrete has set, the production boards 69 are then cleaned and returned to the board magazine 70.

The systems according to FIGS. 12 and 13 can, as shown in the first exemplary embodiment according to FIGS. 8 and 9, be designed for the production of two plates lying next to one another or also for individual production.

The system for the automated production of multilayer boards shown in FIG. 14 comprises an elongated working platform 110 on which a rail track 112 is arranged. A laying carriage 114 and a production carriage 116 are movably supported on this rail track 112.

The laying carriage 114 carries two stacks of natural stone plates 118 arranged side by side, which form the cladding plate of a multilayer plate. The processed stone slabs 118 are stacked with their processed front facing downward. The laying carriage 114 also carries a storage container 120 for a cement adhesive. An overhead rail 122, on which a trolley 124 is suspended, is supported on the laying carriage 114. The trolley 124 carries an application device 126, for example a rotating roller, which can be immersed in the storage container 120 for the cement adhesive. The trolley 124 also carries a storage device 128 formed by a suction head. The end positions of the trolley 124 are determined by limit switches (not shown).

An alignment frame 130 is pivotally articulated on the front end of the laying carriage 114 in the direction of travel. This alignment frame 130 has a plurality of frame legs, which can be brought into abutment on the side surfaces of two stored square natural stone plates 118. Some of the frame legs of the alignment frame 130 are powered (not shown), e.g. Pneumatic cylinder, provided and horizontally movable. These movable frame legs can be brought to bear on two adjacent side surfaces of a deposited natural stone slab 118 in order to press them against the two rigid frame legs and to align them therewith.

The production trolley 116 is mounted on the rail track 112 behind the trolley 114 when viewed in the direction of travel. The production trolley 116 carries a storage container 132 for fresh concrete. In the production cart 116 are a box shape 134 and a ram 136 are vertically movable in opposite relationship. In the production car 116, a loading device 138 and a vibrating table 140 are also arranged to be horizontally movable.

17, a circumferential groove 142 is arranged on the inside of the box shape 134 in the lower region, into which one or more hoses 144 made of an elastic material are inserted. The hoses 144 can optionally be connected to a pressure medium source or to a vacuum pump, so that they protrude inward beyond the inner surface of the box shape or are drawn into the relevant groove 142.

A positioning device is provided to ensure the required relative position between the laying carriage 114 and the production carriage 116. For this purpose, positioning openings 146 are arranged in the work platform 110 at suitable intervals. Both the laying carriage 114 and the production carriage 116 are provided with vertically movable dowel pins 148 which can be brought into engagement with one of the positioning openings 146.

In the event that this positioning device is not sufficient to ensure that the box mold 134 is aligned vertically with a natural stone slab 118 placed on the work platform 110 from the laying carriage 114, an alignment frame, which is similar, can be arranged on the front side of the production carriage in the direction of movement is designed like the alignment frame 130 arranged on the laying carriage 114.

The system described above and shown in FIGS. 14 to 17 operates as follows:
First, the laying stone 114 places the natural stone slabs 118 in pairs on the work platform 110 at the intervals specified by the positioning openings 146. For this purpose, the suction head 128 lifts off the uppermost natural stone plate 118 of the stack and the trolley 124 is moved to the right, whereupon the suction head 128 is lowered in order to place the natural stone plate in the alignment frame 130 on the work platform 110. The movable frame legs of the alignment frame 130 are then brought into contact with the associated power drives on two adjacent side surfaces of the natural stone plate 118 in order to press them onto the two rigid frame legs and to align them. The suction head 128 is then raised and the trolley 124 is moved further to the right, whereupon the application device 126 is lowered in order to provide the sawn-rough back of the natural stone slab 118 with cement adhesive 150. The frame legs of the alignment frame 130 are somewhat higher than the natural stone plate 118, so that the cement adhesive does not run off to the side. Before the cement adhesive is applied, the back of the natural stone plate 118 can be moistened. After the application device 126 has been raised and the trolley 124 has been moved back into its starting position, the alignment frame 130 with the associated power drives is pivoted upward, so that it releases the natural stone plate 118. The laying carriage 114 on the rail track 112 is then moved to the right to the next positioning openings 146.

Depending on the movement of the laying carriage 114, the production carriage 116 is also moved to the right and, by snapping the dowel pins 148 into the associated positioning openings 146, positioned so that the raised two box shapes 134 with two placed on the work platform 110 and one layer 150 out Align the cement glue provided with natural stone slabs 118 vertically. The two box shapes 134 are then lowered until they rest on the work platform 110 and receive the associated natural stone slab 118. The elastic hoses 144 arranged in the grooves 142 of each box shape 134 are then connected to the associated compressed air source. As a result, the tubes 144 expand and protrude from the inside of the box mold 134 and are pressed against the side surface of the natural stone plate 118 and clamp the natural stone plate between them. The two box molds 134 are then raised to an upper position together with the clamped natural stone plates 118, and the vibrating table 140 is moved to the left with the associated power drive in order to support the two natural stone plates 118 from below. The feed device 138 filled with fresh concrete from the storage container 132 is moved to the left with the associated drive on a support until it is aligned with the two box shapes 134, whereupon the fresh concrete is emptied into the two box shapes. It is important that the fresh concrete is applied to the not yet hardened cement glue.

After the loading device 138 has been moved back to its starting position to the right, the two press rams 136 are moved downward with the associated drive. While the plungers 136 press from above onto the fresh concrete introduced into the associated box shape 134, the vibrating table 140 is set in vibration so that the fresh concrete is compacted. As soon as the height of the fresh concrete has decreased to a certain level, the press rams 136 are raised and the vibrating table 140 is moved back into its starting position. In order to reduce the friction, the top of the vibrating table can be coated with a particularly slidable plastic.

The total weight of the multi-layer plate consisting of the natural stone plate 118 and the carrier plate 152 formed from the fresh concrete, which is of the order of 120 kg, is now absorbed by the clamping effect or friction of the inflated hoses 144.

The two box molds 134 are then lowered until the natural stone plates 118 rest on the work platform 110. The hoses 144 are then connected to the vacuum pump so that they are completely in the associated Retract grooves 142. The two box shapes 134 can therefore be pulled up from the associated multilayer plate without the hoses 144 rubbing on the side surface thereof.

This completes a manufacturing cycle and the manufacturing carriage 116 can be moved to the right by a division predetermined by the spacing of the positioning openings 146, whereupon the processes described above are repeated.

In a departure from the exemplary embodiment shown, it is also possible to rigidly connect the production trolley 116 to the storage trolley 114.

With the system described above, square multilayer boards with an edge length of up to 60 cm can be produced. The natural stone slab 118 has a thickness of 4 cm, while the thickness of the concrete layer forming the support slab 152 is 12 cm.

After curing, the cement adhesive 150 forms an elastic adhesive bridge between the natural stone plate 118 and the carrier plate 152, which enables the concrete to shrink without cracking. The multilayer board is therefore characterized by great durability. The multi-layer board proved to be extremely resistant during roll-over tests, and there was no detachment in the area of the cement adhesive. Such a cement adhesive, which forms an elastic adhesive bridge in the hardened state, is sold by PCI Polychemie Augsburg GmbH.

The multilayer board can be handled after two days and easily installed with a vacuum gripper.

1

Außenwand

1a

Außenwand

2

Tragflansch

3

Trennwand

4

Natursteinplatte

4a

Natursteinplatte

5

Tragschicht

6

Stempelplatte

7

Schlauch

8

Anschlußschlauch

9

Schulter

10

Spalt

11

Flächenabschnitt

12

Schrägfläche

13

Nut 13a Nut

14

Vorsprung

15

Fase

16

Flanke

17

Druckfläche

18

Dichtlippe

19

Greif- und Dichtleiste

20

Profilansatz

21

Formmaschine

21a

Formmaschine

22

Rad

23

Schiene

24

Vertikalführung

25

Stempelbär

26

Formrahmen

27

Vorratsilo

28

Füllkasten

29

Horizontalführungen

30

Indexnocken

31

Zentriervorrichtung

32

Schwenkachse

33

Anschlag

34

Rechteckrahmen

35

Lagerarm

36

Anschlagleiste

37

Anschlagleiste

38

Lagerauge

39

Schwenkrahmen

40

Puffer

41

Antriebszylinder

42

Verbundplatte

45

Stoßschutzstreifen

50

Säulenfuß

51

Kette

52

Tragplatten

53

Auflege- und Einstreichstation

54

Portalgerüst

55

Laufkatze

56

Saugkopf

57

Einstreichwalze

58

Stapel

59

Ablagetisch

60

Trog

61

Greiferstation

65

Formmaschine

66

Rütteltisch

67

Brettförderer

68

Schubklinke

69

Fertigungsbrett

70

Brettmagazin

71

Formrahmen

72

Stempelbär

73

Vertikalführung

74

Füllwagen

75

Auflegestation

76

Saugkopf

77

Einstreichstation

78

Einstreichwalze

79

Vorratsgefäß

x

Schrittweite

110

Arbeitsplattform

112

Schienenspur

114

Ablegewagen

116

Fertigungswagen

118

Natursteinplatte

120

Vorratsbehälter

122

Überkopfschiene

124

Laufkatze

126

Aufbringeinrichtung

128

Saugkopf

130

Ausrichtrahmen

132

Vorratsbehälter für Frischbeton

134

Kastenform

136

Preßstempel

138

Beschickungseinrichtung

140

Rütteltisch

142

Nut

144

Schlauch

146

Positionieröffnungen

148

Paßstifte

150

Zement-Kleber

152

Trägerplatte

One skilled in the art can see that the drives assigned to the moving parts of the system described above operate with a corresponding program control be able to achieve an automatic workflow.

1

Outer wall

1a

Outer wall

2nd

Supporting flange

3rd

partition wall

4th

Natural stone slab

4a

Natural stone slab

5

Base course

6

Stamp plate

7

tube

8th

Connecting hose

9

shoulder

10th

gap

11

Surface section

12th

Sloping surface

13

Groove 13a Groove

14

head Start

15

chamfer

16

Flank

17th

Printing area

18th

Sealing lip

19th

Gripping and sealing strip

20th

Profile approach

21

Molding machine

21a

Molding machine

22

wheel

23

rail

24th

Vertical guidance

25th

Stamp bear

26

Molded frame

27th

Storage silo

28

Filling box

29

Horizontal guides

30th

Index cams

31

Centering device

32

Swivel axis

33

attack

34

Rectangular frame

35

Bearing arm

36

Stop bar

37

Stop bar

38

Bearing eye

39

Swing frame

40

buffer

41

Drive cylinder

42

Composite panel

45

Bumper strips

50

Pillar base

51

Chain

52

Support plates

53

Application and coating station

54

Portal scaffold

55

Trolley

56

Suction head

57

Spreading roller

58

stack

59

Filing table

60

trough

61

Gripper station

65

Molding machine

66

Vibrating table

67

Board conveyor

68

Pawl

69

Manufacturing board

70

Board magazine

71

Molded frame

72

Stamp bear

73

Vertical guidance

74

Filling truck

75

Lay-up station

76

Suction head

77

Coating station

78

Spreading roller

79

Storage jar

x

Increment

110

Work platform

112

Rail track

114

Storage trolley

116

Production car

118

Natural stone slab

120

Storage container

122

Overhead rail

124

Trolley

126

Application device

128

Suction head

130

Alignment frame

132

Storage container for fresh concrete

134

Box shape

136

Ram

138

Loading device

140

Vibrating table

142

Groove

144

tube

146

Positioning openings

148

Dowel pins

150

Cement glue

152

Carrier plate

Claims (32)

Process for the production of stone composite panels each consisting of a lower base layer made of concrete in the use position and an upper natural stone panel which are intimately connected to one another, characterized in that
that the natural stone slab (4) turned upside down is placed on a vibrating table and is sealed by a molding frame (26),
that then concrete (5) is introduced into the mold frame and this is compressed by means of a stamp (6) by shaking and
that the concrete layer (5) applied to the natural stone slab (4) is formed by raising the mold frame (26), the stamp (6) initially maintaining its position. A method according to claim 1, characterized in that the natural stone slab (4) prior to being received in the mold frame (26) is precisely and locally aligned by means of a centering device by shifting on its base on the projection of the mold frame. Method according to claim 2, characterized in that movable straightening members (39, 40) of the centering device (31) with at least two intersecting edges press the natural stone slab (4) against corresponding stop bars (36, 37) of the centering device and that the straightening members then press the natural stone plate release again. A method according to claim 1, characterized in that the natural stone slab by means of a horizontally free movable gripper placed on their manufacturing base and is aligned by means of a fixed funnel-shaped guide shaft to the position corresponding to the mold frame. A method according to claim 1, characterized in that an adjustable form frame initially set to plate oversize is lowered so far that it surrounds the natural stone plate and that the frame parts are then moved so far against one another that they lie closely against the side surfaces of the natural stone plate with horizontal orientation . Method according to claim 1, characterized in that after the mold frame (26) has lowered so far that it surrounds the natural stone plate (4), a gripping and sealing strip is pressed against the side surfaces of the natural stone plate from the inner wall of the mold frame, who holds it in the form frame, whereupon the natural stone slab is lifted with it and then placed on the vibrating table or a vibrating table support. Method according to claim 6, characterized in that the finished composite slab (42) is raised again after the application of the concrete (5) by means of the molding frame (26) and then deposited and shaped on the storage surface, of which the natural stone slab (4) previously had been recorded. Method according to Claim 7, characterized in that a molding machine (21) which can be moved on a track (23) and has a vibrating table which can be moved horizontally back and forth in the machine is used such that the natural stone slabs (4) in the mold frame (26) have corresponding arrangements equal distances (x) in the track of the molding machine (21) on the floor that the molding machine (21) accordingly moves these distances (x) step by step and that during each stop on the one hand the natural stone slabs of an arrangement are picked up by means of the mold frame (26), provided with the concrete layers (5) and placed on the floor as finished composite slabs (42) and 4) an arrangement lying ahead in the direction of travel can be aligned by means of a centering device (31) on the relevant projection of the mold frame. Method according to claim 7, characterized in that a stationary molding machine (21a) is used with a vibrating table which can be moved horizontally back and forth in the machine, and in that by means of a horizontal conveyor (x) which moves gradually in a plane below the vibrating table at equal intervals (x) 51) the natural stone slabs (4) are fed to the molding machine (21a) and the finished composite slabs (42) are led away from the molding machine. Method according to claim 9, characterized in that the freshly manufactured composite panels (42) are removed from the horizontal conveyor by means of a gripper (61) which clamps the natural stone panel of the finished product on two opposite side surfaces and can thereby carry it. Method according to Claim 1, characterized in that a stationary molding machine (65) with a non-displaceable vibrating table (66) is used, that the natural stone slabs (4) placed on the production boards (69) together with these production boards (69) by means of an in Equal distances (x) gradually moving horizontal conveyor of the molding machine (65) that the production boards (69) are placed on the vibrating table (66) and shaken and that the finished Composite plates (42) leave the molding machine on the respective production board by means of the horizontal conveyor. Method according to one of the preceding claims, characterized in that the stacked natural stone slabs are automatically separated and laid out by means of a horizontally and vertically movable suction head. Method according to one of the preceding claims, characterized in that the stacked natural stone slabs (58) are automatically washed on their upward-facing underside before being coated with concrete and then coated automatically with a concrete adhesive. Method according to claim 1, characterized in that in order to improve the connection of the concrete with the natural stone slab, a concrete strengthener, adhesive or adhesive is applied to the natural stone surface. Apparatus for carrying out the method according to claim 1, characterized in that the mold frame has sealing and stripping elements on its inside in the thickness range of the natural stone slab (4). Device for carrying out the method according to claim 1, characterized in that the mold frame (26) has on its inside in the thickness range of the natural stone slab (4) a circumferential groove (13) into which an elastic hose (7) is inserted, the internal pressure of which is controllable is. Apparatus according to claim 16, characterized in that the hose (7) forms a closed ring, the connecting line (8) passes through the wall of the mold frame. Device according to claim 16, characterized in that the groove (13) is narrowed towards the groove opening by bead-like projections (14) of the groove side walls. Apparatus according to claim 16, characterized in that the hose has flat flanks (16) which can be placed on flat groove side surface sections. Apparatus according to claim 19, characterized in that the hose has a flat pressure surface (17) extending between the flanks. Apparatus according to claim 16, characterized in that the hose has a pressure surface provided with sealing lips (18) or grooves. Apparatus according to claim 16, characterized in that a cross-sectionally rectangular gripping and sealing strip (19) is formed on the hose. Apparatus according to claim 16, characterized in that the hose is held on the back, so that it retracts into the groove due to its elasticity or due to the application of negative pressure (Fig. 7). Apparatus according to claim 16, characterized in that an elastic shock protection strip (45) is inserted above the groove (13a) containing a hose into a further groove parallel to the inside of the mold frame. Device according to claim 24, characterized in that the upper edge of the shock protection strip (45) is higher and the lower edge of the shock protection strip (45) is lower than the horizontal upper surface (46) of the natural stone slab (4a). Apparatus for carrying out the method according to claim 4, characterized in that the mold frame has a circumferential groove on its inside in the thickness range of the natural stone slab and that in the groove sections of each wall of the mold frame there is provided a strip made of plastic which can be moved perpendicular to the wall. Device for carrying out the method according to claim 1, characterized in that the inner surface sections (11) of the mold frame (26) corresponding to the thickness of the natural stone slab (4) are set back with respect to the remaining inner surface. Device for carrying out the method according to claim 2, characterized in that the centering device (31) is pivotally mounted on the side of the molding machine (21) on which the natural stone slabs (4) enter it. Apparatus according to claim 3, characterized in that the centering device is designed as a frame (34), the attachment strips (36, 37) being arranged on two frame legs and the straightening members (39, 40) being movably mounted on the other frame legs. Device for carrying out the method according to claim 8, characterized in that index cams (30) are arranged on at least one travel rail (23), to which the molding machine (21) couples in a form-fitting manner during its respective stop. Apparatus according to claim 30, characterized in that the index cams (30) are arranged at a distance (x) which is equal to the horizontal distance of the Centering device (31) from the mold frame (26) or equal to an integer fraction of this distance. Device for carrying out the method according to claim 1, characterized in that the vibrating table has a support made of an elastic material.

Images