EP2527117B1 - Method and device for manufacturing artificial stone - Google Patents

Method and device for manufacturing artificial stone Download PDF

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Publication number
EP2527117B1
EP2527117B1 EP10844064.5A EP10844064A EP2527117B1 EP 2527117 B1 EP2527117 B1 EP 2527117B1 EP 10844064 A EP10844064 A EP 10844064A EP 2527117 B1 EP2527117 B1 EP 2527117B1
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EP
European Patent Office
Prior art keywords
mold
chips
artificial stone
raw material
vibration
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP10844064.5A
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German (de)
English (en)
French (fr)
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EP2527117A4 (en
EP2527117A2 (en
Inventor
Hae-Seung Ko
Chang-Hwan Park
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
LX Hausys Ltd
Original Assignee
LG Hausys Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from KR1020100005523A external-priority patent/KR101581962B1/ko
Application filed by LG Hausys Ltd filed Critical LG Hausys Ltd
Publication of EP2527117A2 publication Critical patent/EP2527117A2/en
Publication of EP2527117A4 publication Critical patent/EP2527117A4/en
Application granted granted Critical
Publication of EP2527117B1 publication Critical patent/EP2527117B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/082—Producing shaped prefabricated articles from the material by vibrating or jolting combined with a vacuum, e.g. for moisture extraction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties

Definitions

  • the present invention relates to a method and device for manufacturing artificial stone, and more particularly to a method and device for manufacturing artificial stone, which maximizes a deposition rate of chips exposed to a surface of artificial stone, thereby achieving more natural expression of an external appearance of the artificial stone while improving resistance against abrasion and staining.
  • artificial stone for exterior or interior building materials is produced by mixing various kinds of natural stone chips in a cement base, followed by pressing or simple vibration.
  • the EP 0 492 555 A1 discloses a composition and a process for the production of artificial marble or granite, wherein a liquid, polymerizable binder and a mineral filler are poured into a mould, the mixture is compacted, optionally under vacuum and optionally by shaking or vibration to eliminate occluded air; the binder is thermally polymerized and finally the obtained slab or block is finished.
  • a manufacturing method of artificial stones is further described in KR 2008 0098973 , the method comprising the mixing of small and large chips of defined size and mixing ratio selected from a resin chip, a native rock chip, and a glass chip, and the use of a vibrator.
  • WO 97/27982 A1 discloses the preparation cementitious products in form of tiles, slabs or blocks by mixing a granulated stone material and a binding mix comprising cement, water and a plasticizer, spreading the resulting mixture in a mould, subjected it to a first very short deaeration step under the effect of a very high vacuum and to a subsequent vibration step under a lower vacuum, after which the mould goes on to setting and hardening steps.
  • the present invention is directed to solving such problems of the related art and provides a method and device for manufacturing artificial stone, which maximizes a deposition rate of chips exposed to a surface of artificial stone by mixing two or more kinds of chips in a predetermined ratio and vibrating the mixture in a mold to settle the chips on the bottom of the mold, thereby achieving more natural expression of an external appearance of the artificial stone while improving resistance against abrasion and staining.
  • the method for manufacturing artificial stone includes the following modified steps: (c) applying primary vibration to the mold using a vibrator at normal pressure and a vibration rate of 1800 to 7000 revolutions per minute (rpm) for 10 seconds to 1 minute to uniformly disperse the raw material in the mold; (d) evacuating air around the mold for 10 to 30 seconds to create a vacuum of 30 mmHg or more around the mold in order to remove bubbles from the raw material; and (e) applying secondary vibration to the mold using a vibrator at normal pressure and a vibration rate of 1800 to 7000 rpm for 30 seconds to 5 minutes to uniformly disperse the raw material in the mold to mold artificial stone.
  • the device for manufacturing artificial stone is modified by including: a vibrator for primarily vibrating the mold at normal pressure and a vibration rate of 1800 to 7000 rpm for 10 seconds to 1 minute; a vacuum generation unit including a chamber receiving the mold transferred from the primary vibration unit and a vacuum generator capable of evacuating air from the chamber for 10 to 30 seconds to create a vacuum of 30 mmHg or more in the chamber; and a secondary vibration unit including a vibrator for secondarily vibrating the mold transferred from the vacuum generation unit at normal pressure and a vibration rate of 1800 to 7000 rpm for 30 seconds to 5 minutes.
  • two or more kinds of chips are mixed in a predetermined ratio and the mixture is vibrated in a mold to settle the chips on the bottom of the mold to maximize a deposition rate of chips exposed to a surface of artificial stone, thereby achieving more natural expression of an external appearance of the artificial stone while improving resistance against abrasion and staining.
  • artificial stone includes any cement-based artificial stone or resin-based artificial stone, which can be used as interior building materials or exterior building materials.
  • Fig. 1 is a flowchart of a method for manufacturing artificial stone according to one embodiment of the present invention.
  • the method for manufacturing artificial stone according to the embodiment includes: (a) mixing two or more kinds of chips having different grain sizes with a raw material for artificial stone; (b) injecting the raw material mixed with the chips into a mold; and (c) applying primary vibration to the mold using a vibrator at normal pressure and a vibration rate of 1800 to 7000 rpm for 10 seconds to 1 minute to uniformly disperse the raw material in the mold.
  • the method includes (d) evacuating air around the mold for 10 to 30 seconds to create a vacuum of 30 mmHg or more around the mold in order to remove bubbles from the raw material; and (e) applying secondary vibration to the mold using a vibrator at normal pressure and a vibration rate of 1800 to 7000 rpm for 30 seconds to 5 minutes to uniformly disperse the raw material in the mold to mold artificial stone.
  • the raw material for artificial stone may be a resin or a cement slurry.
  • the resin according to this embodiment may include at least one selected from the group consisting of, for example, acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polycarbonate, poly(methyl methacrylate), polyethyleneterephthalate, and styrene-methyl methacrylate copolymers.
  • the raw material for artificial stone may be a cement slurry, which may include 25 to 35 percent by weight of water based on 100 parts by weight of cement.
  • the cement slurry will undergo deterioration in workability and fluidity, and if the amount of water in the cement slurry exceeds 35 wt%, the final cement product will undergo deterioration in mechanical properties.
  • the mixing operation (a) may include mixing 125 to 200 parts by weight of chips having a grain size of 3 to 9 mm and 50 to 80 parts by weight of chips having a grain size of 1 to 3 mm based on 100 parts by weight of the raw material.
  • the raw material for artificial stone may be mixed with two or more kinds of chips having different grain sizes.
  • the chips may include at least one kind of chip selected from the group consisting of resin chips comprising at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, poly(methylmethacrylate), polyethyleneterephthalate, and styrene-methyl methacrylate copolymers; glass chips; colored glass chips; natural stone chips; and colored natural stone chips produced by coloring pulverized natural stone pieces.
  • the cement slurry may be comprised of 170 to 250 parts by weight of natural stone chips having a grain size of 3 to 9 mm, 50 to 100 parts by weight of natural stone chips having a grain size of 1 to 3 mm, 30 to 100 parts by weight of natural stone powder, 25 to 35 parts by weight of water, and 1 to 3 parts by weight of a plasticizer, based on 100 parts by weight of the cement slurry.
  • typical additives known in the art may further be added to the slurry.
  • the raw material mixed with the chips is injected into a mold and is subjected to primary vibration for 10 seconds to 1 minute to achieve uniform dispersion of the raw material in the mold. If vibration is applied for a period of time less than 10 seconds, it can be difficult to obtain uniform dispersion of the raw material, and if vibration is applied for a period of time exceeding 1 minute, the mixed raw material can be excessively hardened, thereby making it difficult to remove bubbles therefrom.
  • the raw material for artificial stone mixed with the chips may be spread in a constant thickness within the mold by application of primary vibration, which may be performed at a vibration rate of 1800 to 7000 rpm. If the vibration rate is less than 1800 rprn, it can be difficult to spread the mixed raw material to a uniform thickness within the mold, and if the vibration rate exceeds 7000 rpm, the raw material is likely to escape from the mold during application of primary vibration.
  • the mold is placed in a typical vacuum chamber, which in turn is evacuated for 10 to 30 seconds to create a vacuum of 30 mmHg or more in the chamber in order to remove bubbles from the raw material.
  • pores formed on the surface of the raw material through which the bubbles are removed from the raw material during the evacuation operation may be filled with the raw material during application of secondary vibration, so that the artificial stone has a dense structure and good mechanical strength.
  • the molded artificial stone is sequentially subjected to typical processes, such as curing, releasing and surface grinding, followed by cutting, inspection, and packaging, thereby providing a final product.
  • Fig. 2 is a conceptual diagram of a device for manufacturing artificial stone according to one embodiment of the present invention.
  • the device 1 includes a primary vibration unit 10, a vacuum generation unit 20, and a secondary vibration unit 30, and a typical transfer mechanism (for example, a belt conveyer) disposed between the respective units to transfer the mold to the subsequent unit.
  • a typical transfer mechanism for example, a belt conveyer
  • the mold is transferred between the respective units and is indicates by different reference numerals 13, 23 and 33 for convenience of description of the mold placed in each of the units.
  • the primary vibration unit 10 includes a raw material weighing instrument 14 capable of weighing a predetermined amount of a mixed raw material for artificial stone S, a mold 13 into which the weighed raw material S is injected from the weighing instrument 14, and a vibrator 11 for vibrating the mold 13 at normal pressure and a vibration rate of 1800 to 7000 rpm for 10 seconds to 1 minute.
  • the mold 11 may be supported on a frame 12 or the like during application of vibration, and the frame 12 may be connected to a bottom surface, on which the frame 12 is installed, via an elastic member 15 so as to maintain elasticity upon application of vibration.
  • the vacuum generation unit 20 includes a chamber 21 which receives the mold 23 transferred from the primary vibration unit 10, and a vacuum generator 24 which is capable of evacuating air from the chamber 21 for 10 to 30 seconds to create a vacuum of 30 mmHg or more in a space 25 of the chamber.
  • the operation (d) of the method may be performed using such a vacuum generation unit 20.
  • the secondary vibration unit 30 includes a vibrator 31 for vibrating the mold 33 transferred from the vacuum generation unit 20 at normal pressure and a vibration rate of 1800 to 7000 rpm for 30 seconds to 5 minutes.
  • the mold 33 may be supported on a frame 32 or the like during application of secondary vibration, and the frame 32 may be connected to a bottom surface, on which the frame 32 is installed, via an elastic member 35 so as to maintain elasticity upon application of vibration.
  • Each of the units constructed as described above constitutes a single instrument and allows the mold to be transferred therefrom to the next unit after operation corresponding to each unit, thereby enabling continuous operation and mass production.
  • Cement-based artificial stone was produced using natural stone chips.
  • the cement slurry acting as a binder for artificial stone was placed in a mold.
  • the cement slurry was comprised of about 150 parts by weight of natural stone chips having a grain size of about 5 mm, about 100 parts by weight of natural stone chips having a grain size of about 2 mm, about 50 parts by weight of natural stone powder, about 30 parts by weight of water, and about 2 parts by weight of a plasticizer, based on 100 parts by weight of the cement slurry.
  • the cement slurry was placed in the mold and subjected to primary vibration for about 15 seconds using a vibrator to spread the cement slurry to a constant thickness within the mold, which in turn was placed in a vacuum chamber. Then, the vacuum chamber was evacuated for about 25 seconds to create a vacuum within the chamber in order to remove bubbles from the cement slurry. Then, the mold was subjected to secondary vibration for about 3 minutes using a vibrator to maximize the deposition rate of the chips by settling the natural chips on the bottom of the mold, followed by curing the cement slurry for 12 hours at 40 to 50°C under constant moisture conditions.
  • the cured product was released from the mold and subjected to typical grinding and cutting processes for artificial stone to provide 400 mm(L)x400 mm(W)x20 mm(T) artificial stone.
  • the artificial stone according to the example has high bending strength and a low absorption rate.
EP10844064.5A 2010-01-21 2010-12-23 Method and device for manufacturing artificial stone Active EP2527117B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR1020100005523A KR101581962B1 (ko) 2009-01-21 2010-01-21 인조석의 제조방법 및 제조장치
PCT/KR2010/009241 WO2011090268A2 (ko) 2010-01-21 2010-12-23 인조석의 제조방법 및 제조장치

Publications (3)

Publication Number Publication Date
EP2527117A2 EP2527117A2 (en) 2012-11-28
EP2527117A4 EP2527117A4 (en) 2013-12-11
EP2527117B1 true EP2527117B1 (en) 2016-11-09

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EP10844064.5A Active EP2527117B1 (en) 2010-01-21 2010-12-23 Method and device for manufacturing artificial stone

Country Status (4)

Country Link
EP (1) EP2527117B1 (ko)
JP (1) JP5443611B2 (ko)
CN (1) CN102666045B (ko)
WO (1) WO2011090268A2 (ko)

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CN103072181B (zh) * 2012-12-14 2015-03-25 叶香菲 石棉瓦的成型方法
CN104802279A (zh) * 2014-01-23 2015-07-29 吴文鸿 一种花纹人造石的制备方法
WO2018002807A1 (en) * 2016-06-29 2018-01-04 Officine Maccaferri S.P.A. Machinery, plant and process for producing artificial stones
CN109676842A (zh) * 2019-02-15 2019-04-26 宁波志胜科技有限公司 一种汽车内饰件生产工艺及其生产装置
CN111348877A (zh) * 2020-03-16 2020-06-30 晋江市美石美刻工艺美术品有限公司 一种美观型生态石制作工艺和控制系统

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SU1433803A1 (ru) * 1986-12-30 1988-10-30 Средневолжский Филиал Бюро Внедрения Центрального Научно-Исследовательского И Проектно-Экспериментального Института Организации,Механизации И Технической Помощи Строительству Способ изготовлени бетонных изделий
JPS6437449A (en) * 1987-08-03 1989-02-08 Sony Corp Production of synthetic granite
IT1244480B (it) * 1990-12-21 1994-07-15 Enichem Sintesi Composizione formante marmo o granito artificiali
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Also Published As

Publication number Publication date
JP2013508200A (ja) 2013-03-07
EP2527117A4 (en) 2013-12-11
WO2011090268A2 (ko) 2011-07-28
JP5443611B2 (ja) 2014-03-19
CN102666045A (zh) 2012-09-12
EP2527117A2 (en) 2012-11-28
WO2011090268A3 (ko) 2011-11-24
CN102666045B (zh) 2014-12-03

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