ES2951481T3 - Apparatus and method for spraying color into the cracks of a moving formed quartz slab to create veins in an engineered stone - Google Patents

Abstract

An apparatus including a first device that moves a first portion of a soft, moist, lightly pressed slab out of alignment with the bulk of the slab and thereby introduces a first crack into the slab; and a device for spraying a first colored material into the first crack of the slab. The first device that misaligns the first portion of the slab with the rest of the slab may include a first cylinder. The device for spraying the first colored material into the first crack of the slab may include a robotic apparatus. In at least one embodiment, the apparatus may also include a second device that misaligns a second portion of the slab with the bulk of the slab and thereby introduces a second crack into the slab. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Apparatus and method for spraying color into the cracks of a moving formed quartz slab to create veins in an engineered stone

Field of Invention

This invention relates to improved methods and apparatus relating to quartz slabs.

Background of the Invention

Quartz is the second most abundant mineral in the Earth's crust and one of the hardest natural materials. One of its many uses is in "engineered stone." Engineered stone, which includes quartz, has become a common choice for surfaces and countertops in many countries around the world. Its applications include kitchen and bathroom countertops, tables and desks, floor tiles, food service areas, wall coverings and various other horizontal and vertical applications.

The production of engineered stone generally involves particulate materials such as ground quartz rock, crushed glass, rocks, pebbles, sand, shells, silicon and other inorganic materials combined with polymers, binders, resins, colorants, dyes, etc. The particulate material(s) may have variable sizes ranging from a four hundred mesh particle size to a four mesh particle size with multiple materials of different sizes used simultaneously. The polymer may include agents such as a binder, hardener, initiator or a combination thereof. The particulate materials and polymers, binders, resins, colorants, dyes, etc. are then mixed, resulting in a slightly wet mixture. This initial mixture can be processed through a crusher to reduce the size of the combined particles. The resulting finer mixture can be poured into a supporting mold, tray or other supporting structure. The mold or tray containing the wet mixture is then moved to a conveyor belt with a backing sheet, then a processed wet "slab" is moved to a vacuum press machine to compress the material. The compressed material is then placed in a curing machine to be heated into a hardened quartz slab. After curing, the hardened slab is usually moved to a crusher to reduce it to the desired thickness, followed by a polisher to finish the product.

Quartz-based stone has many advantages over natural stone such as marble and granite. Compared to these natural stones, quartz is harder, stronger, absorbs less water and is more resistant to stains, scratches, breakage, chemicals and heat. One of the drawbacks of quartz is that it is perceived to lack natural and random-looking veins and color patterns compared to natural stones. This invention relates to a method of producing a quartz-based slab with single-color patterns or multiple-color patterns and/or veins.

Examples of apparatus designed to work quartz-based stone include document FR1314960A.

Compendium of the Invention

According to the first aspect of the invention, there is provided an apparatus according to claim 1 comprising a first device that is configured to be actuated vertically to cause a force to be applied to a first part of a slab to move it. vertically out of alignment with an area of the slab surrounding the first part of the slab and therefore produces a first crack in the first part of the slab, wherein the first device is configured to be located between the first part and a soil surface, when the first crack occurs; and a device for depositing a material having a color configured to deposit a first material having a color in the first crack of the slab, so that the first crack has the first deposited material becoming a vein having the color of the first material; and further comprising a second vertically operable device configured to cause a force to be applied to a second portion of the slab to move vertically out of alignment with an area of the slab surrounding the second portion of the slab and , therefore, produces a second crack in the second part of the slab, where the second device is configured to be located between the second part and a ground surface, when the second crack occurs; wherein the device for depositing a material having a color is configured to deposit a second material having a color in the second crack of the slab, so that the second crack has the second deposited material becoming a vein having the color of the second material; and characterized in that the apparatus is configured so that while the first device applies force to the first part to keep the first crack open, the first crack has the first material deposited, wherein the apparatus is configured so that while the second device applies forces the second part to keep the second crack open, the second crack has the second material deposited.

In at least one embodiment, the apparatus may also include a conveyor device that is configured to move in a first direction; wherein the conveyor device is configured to move the slab over at least a portion of the first device that moves the first portion of the slab out of alignment with the bulk portion of the slab.

The conveyor device may be configured to move the slab over at least a portion of the device that moves the second portion of the slab out of alignment with the bulk portion of the slab.

The apparatus may further comprise a plurality of additional devices that are configured to cause a corresponding plurality of additional slab parts to move vertically out of alignment with corresponding areas of the slab surrounding the corresponding plurality of additional slab parts and , therefore, produces a corresponding plurality of additional cracks in the plurality of additional parts of the slab, where each plurality of devices is configured to be located between its corresponding part and the ground surface, when the corresponding crack occurs; and wherein the device for depositing the material having a color is configured to deposit material having a color in the plurality of additional cracks of the slab, so that the plurality of additional cracks of the slab are converted into veins having the color of the particular deposited material.

The first device and the plurality of additional devices may be arranged in an array of a plurality of rows and columns.

The first device may be a cylinder and the second device may be a second cylinder.

Each first device and a plurality of said second devices may be a cylinder.

The apparatus may further comprise a computer processor that controls the movement of the first device, the second device and the deposit device.

According to a second aspect of the invention, a method according to claim 9 is provided.

The method may employ additional method steps, and may employ the structure as set forth above and as further set forth in the present application.

Brief description of the drawings

Figure 1 shows a top, left and front perspective view of an apparatus according to an embodiment of the present invention, with the apparatus of Figure 1, in a first state;

Figure 2 shows a top, left and front perspective view of a part of the apparatus of Figure 1, with part of the apparatus of Figure 1 visible in Figure 2, which is not visible in Figure 1, with the apparatus of Figure 1 in the first state;

Figure 3 shows a close-up side view of a part of the apparatus of Figure 1, with the apparatus of Figure 1 in the first state;

Figure 4 shows a perspective view of the apparatus of Figure 1, with the apparatus of Figure 1 in a second state;

Figure 5 shows a slat with wheels that can be used in place of a lifting bar in the apparatus of Figure 1;

Figure 6 shows the image of a slab with a crack formed according to an embodiment of the present invention;

Figure 7 shows a side view in which some of the components of the apparatus of Figure 1 have been replaced;

Figure 8 shows a simplified block diagram of a computer processor and components that communicate with and/or are controlled by the computer processor; and

Figure 9 shows a perspective view of a robotic apparatus, a spray device, a plate with an array of openings according to an embodiment of the present invention, an array of cylinders and holes and an apparatus for transporting a slab, without that the slab is shown;

Figure 10 shows a perspective view of the robotic apparatus, the spray device, the slab, the sheet, the plate covered by the slab and the apparatus for transporting the slab;

Figure 11 shows a front view of the robotic apparatus, the projection device, the slab, the sheet, the plate covered by the slab and the apparatus for transporting the slab, with all cylinders in their lowered positions;

Figure 12 shows a front view of the robotic apparatus, the projection device, the slab, the sheet, the plate covered by the slab and the apparatus for transporting the slab with a raised cylinder, causing the formation of one or more cracks in the top of the slab;

Figure 13 shows a perspective view of the robotic apparatus, the spray device and the plate with the array of apertures according to one embodiment of the present invention, with specific plate openings shown darkened indicating raised cylinders and others not darkened. indicating lowered cylinders in a first state for the plurality of cylinders;

Figure 14 shows a perspective view of the robotic apparatus, the spray device and the plate, showing different obscured openings that indicate raised cylinders and other non-obscured openings that indicate lowered cylinders, in a second state for the plurality of cylinders, which is different from Figure 13;

Figure 15 shows a perspective view of the robotic apparatus, the spray device and the plate, showing different obscured openings that indicate raised cylinders and other non-obscured openings that indicate lowered cylinders in a third state for the plurality of cylinders, which is different from the Figs.

13 and 14;

Figure 16 shows a perspective view of the robotic apparatus, the spray device, a slab that has been processed through the first three states of Figures 13-15 to a fourth and final state, the sheet, the plate covered by the slab, and a part of an apparatus for transporting the slab;

Figure 17 shows a simplified block diagram of a computer processor and components that communicate with and/or are controlled by the computer processor; and

Figure 18 shows a front view of the robotic apparatus, the spray device, the slab, the sheet, the plate covered by the slab and part of the apparatus for transporting the slab, with all cylinders except one, extended over the plate so that the slab rests on the cylinders and not on the plate, and cracks occur due to the descent of a cylinder.

Detailed description of the drawings

Figure 1 shows a top, left and front perspective view of an apparatus 1 according to an embodiment of the present invention, with the apparatus of Figure 1, in a first state. The apparatus 1 includes the servomotor 2, the servomotor 4, the servomotor 6, rods or tracks 8 and 10, lifting bars 12 and 14, spray bars 20 and 22, a plurality of nozzles 24, a plurality of nozzles 25, the spray bar structure 41, the spray bar rotation servo motor 40, the conveyor belt 26, the roller 28, the formed quartz slab 30 and the backing sheet 32. The formed quartz slab 30 in Figure 1 It appears in a soft or moist form.

The apparatus 1 also includes the U-shaped member 3, the post 5, the member 7, the member 9, the member 11, the gear 13 and the gear 15. The U-shaped member 3 may have openings 3a and 3b through which the bar or tracks 8 and 10 are inserted.

In operation, the servomotor 2 can move the U-shaped member 3 to cause the U-shaped member 3 to slide in the directions D1 or D2, on the rods or tracks 8 and 10, while the rods or tracks 8 and 10 remain stationary.

Furthermore, the lifting bars 12 and 14 and the spray bars 20 and 22 together can be rotated to change their orientation with respect to the conveyor belt 26, with respect to the U-shaped member 3 and with respect to the longitudinal direction of the conveyor belt. For example, in Figure 1, the conveyor belt 26 is shown perpendicular or substantially perpendicular to the rods or tracks 8 and 10, and with respect to the direction arrows or directions D1 and D2, but the lifting bars 12 and 14 and the spray bars 20 and 22 can be rotated (while the conveyor belt 26 remains stationary) to form a different angle with respect to the rods or tracks 8 and 10, and with respect to the direction arrows or directions D1 and D2, and with respect to the conveyor belt 26 or rotated so that it is parallel to the rods or tracks 8 and 10, and parallel to the direction arrows or directions D1 and D2.

Furthermore, the servomotor 6 can drive the lifting bars 12 and 14 up and down in the directions U1 and D1, shown in Figure 3, driving the members 7, 11 and 17 up and down to make the members 19 and 21 move up and down, and the attached lifting bars 12 and 14 move up and down in the directions U1 and D1, shown in Figure 3.

The servomotor 4 can drive the lift bars 12 and 14 and the servomotor 40 can drive the spray bars 20 and 22 from zero to one hundred and eighty degrees, with respect to the conveyor belt 26. For example, in Figure 1, the bars lift bars 12 and 14 and the spray bars 20 and 22 are at ninety degrees with respect to the length of the conveyor belt 26. The servomotor 4 can drive the lift bars 12 and 14, the servomotor 40 can drive the spray bars 20 and 22, to orient the components 12, 14, 20 and 22, parallel to the conveyor belt 26 (ninety degree rotation of Figure 1), or at some other angle, or a rotation of one hundred and eighty degrees that causes the ends 20a and 20b exchange locations and ends 22a and 22b exchange locations.

In at least one embodiment, the colorant is sprayed onto a surface and/or into surface cracks, such as cracks 16 and 18 shown in Figure 1, of the slab 30 through one or more nozzles 24 and 25. .

The conveyor belt 26 and roller 28 may be part of an overall conveyor device, and the belt 26 and roller 28 may be driven by a motor not shown in Figure 1.

Figure 2 shows a top, left and front close-up perspective view of a part of the apparatus 1 of Figure 1, with part of the apparatus 1 of Figure 1 visible in Figure 2, which is not visible in Figure 1 , with the apparatus 1 of Figure 1 in the first state.

Figure 3 shows a close-up side view of a part of the apparatus 1 of Figure 1, with the apparatus 1 of Figure 1 in the first state.

Figure 4 shows a perspective view of the apparatus 1 of Figure 1, with the apparatus 1 of Figure 1 in a second state, in which the lifting bars 12 and 14, together with the spray bars 20 and 22 have been driven to be at a substantial longitudinal angle with respect to the conveyor belt 26 by the servomotor 4 and by the servomotor 40.

Figure 5 shows a slat with wheels that can be used in place of a lifting bar in the apparatus of Figure 1;

Figure 6 shows an image of a soft or wet slab 130 (which may be similar or identical to the slab 30 of Figure 1) with a crack 130a formed in accordance with one or more embodiments of the present invention.

Figure 7 is a side view, in which components 2, 3, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17, 19 and 21 have been removed and replaced by an apparatus 100 including component 114 that can be adjusted upward in the direction U2 or downward in the direction D2 to adjust to a different height level with respect to the level of the surface of the belt 26. This may also cause The surface of the quartz slab 30a' passing through may crack at a different height point, but the crack lines generally only occur in a direction perpendicular to the direction of movement of the conveyor belt. In Figure 7, the slab is identified as slab 30', the surface of the slab as 30a', the cracks as 16' and 18', because the cracks 16' and 18' will be somewhat different from the cracks 16 and 18, and therefore, slab 30' and slab surface 30a' will be somewhat different from the soft and/or moist and/or wet slab 30 and surface 30a shown in Figure 1.

In at least one embodiment, the long lifting bars 12 and 14 can be driven upward in the direction U1, shown in Figure 3, by a servomotor 6 to push up the conveyor belt section 26 while a slab The soft, wet formed quartz slab 30 passes through the conveyor belt 26, causing the surface of the quartz slab at points 16 and 18, above the lifting bars 12 and 14, respectively, to crack, along along the longitudinal direction of the lifting bars 12 and 14.

Each of the spray bars 20 and 22 contains a series of spray nozzles, 24 and 25, respectively, positioned on the passing quartz slab 30 on the belt 26, controlled by a computer processor 202, and will send bursts of dye 27 and 29, shown in Figure 3, on cracks 16 and 18 of quartz slab 30.

In at least one embodiment, the spray bars 20 and 22 are always in a fixed orientation with respect to the lift bars 12 and 14, such that the spray bar 20 is always just above the lift bar 12 and the Spray bar 22 is always just above the left bar 14, driven by servomotor 4 and 40, controlled by computer processor 202.

Generally, in at least one embodiment, if the lift bars 12 and 14 are rotated to a certain extent by the servomotor 4, the servomotor 40 is programmed to rotate the spray bars 22 and 24 to exactly the same degree to align the components. 12, 14 with 22, 24, as shown, for example, in Figure 4, so that in this way, when spraying occurs, the color can enter the cracks, such as cracks 16 and 18, as is shown in Figure 3. Generally, it is critical, in at least one embodiment, that the components 12, 14 and 22, 24 be controlled, for example, by the computer processor 202 to be in the same orientation, as shown. shown in Figure 4, to place the spray bar 20 directly above and aligned with the lift bar 12, and the spray bar 22 directly above and aligned with the lift bar 14, so that the series of nozzles 24 directly above the lift bar 12 and the series of nozzles 25 directly above the lift bar 14 can spray colored material into the cracks produced by the lift bars 12 and 14. If the spray bar 20 is not aligned with the lift bar 12 and spray bar 22 is not aligned with lift bar 14, most of the color material will be sprayed out of the cracks

Furthermore, generally speaking, as shown in Figure 3, cracks 16 and 18 typically occur, in at least one embodiment, when the slab portion 30 passes through a different height level, such as e.g. , measured from the gear or component 13. Due to the lifting bar 12, a first portion of the slab 30 moves upward out of alignment with the majority of the slab 30. Due to the lifting bar 14, a second part of slab 30 moves upward out of alignment with the majority of slab 30, at the same time the first part of slab 30 moves out of alignment with the majority of slab 30. After that part of slab 30 pass through that different height level, for example after a part of the slab slab 30 passes the lifting bar 12, the crack 16 will close. Similarly, after a part of the slab 30 passes the lifting bar 14, the crack 18 will close. Spray color material on cracks 16 and 18 is generally scheduled to occur when cracks 16 and 18 occur, not after.

In at least one embodiment of the present invention, a different height level causes a portion of a formed quartz slab surface 30a to crack at a different height level point, while a crack exists, colored material is sprayed on cracks, such as 16 and 18. Spraying of colored material can be performed by a person with a spray gun, or by a spray bar or bars, such as 20 and 22, as described in this invention, or by a robot with a track to detect the crack area and spray into the cracks.

Furthermore, the direction of the crack lines, such as lines 16 and 18, can be controlled by the rotating lifting bars 12 and 14 in one or more embodiments of the present invention.

The lifting bars 12 and 14 are seated on the members 19 and 21, which are connected to the gear 13, and which can cause the lifting bars 12 and 14 to rotate in the desired direction, from zero to one hundred and eighty degrees, driven by a servomotor 4 and controlled by the computer 202. The lifting bars 12 and 14 can be raised when cracks are needed in a certain area of the surface of a quartz slab passing through the belt, and at the same time when cracks occur cracks, dye is sprayed into the cracks, as shown for cracks 16 and 18, with dye 27 and 29 shown in Figure 3, controlled by computer processor 200.

In general, the higher the lifting bars 12 and 14 are, the wider the cracks 16 and 18 will be on the surface 30a of the through quartz slab 30, and therefore, when sprayed, the deeper the colorant will be. 27 and 29 on the internal walls, such as 16a and 18a of cracks 16 and 18, and the dye 27 and 29 will be denser on the walls, such as 16a and 18a of cracks 16 and 18. That is, Generally, greater penetration means darker, deeper crack veins.

When crack veins are needed in a substantial longitudinal direction (along slab 30) in a quartz slab, bars 12 and 14 are rotated to that orientation, as shown in Figure 4, and the structure of the bar, including bars 12 and 14, can be moved on tracks or rods 8 and 10, so that it can be moved in and out under the conveyor belt 26 to position it in the desired area. If more crack lines are needed in the longitudinal direction, the conveyor belt 26 can be stopped, in response to the computer processor 202, and the lifting bar structure, including bars 12 and 14, can continue moving on the tracks. 8 and 10 to a desired area and the colorant can be sprayed into the cracks above the lifting bars in the manner described above.

The lifting bars 12 and 14 may be equipped with bearings, so they may have less resistance when lifted against the moving conveyor belt 26. For example, in Figure 5, a slat with wheels 52 can be used as a lifting bar. lift, instead of lift bar. 12, to achieve the same result. In such an embodiment, the circular cross section of the rotating wheel 52a of the wheeled railing 52 can be replaced in Figure 3 by the circular cross section of the bar 12.

Figure 7 shows an apparatus 100 that replaces various components shown in Figure 3. The apparatus 100 may include a tie plate 114, a first belt structure including the belt 104 and rollers 102 and 106, and a second belt structure including the belt 110, and the rollers 108 and 112. By adjusting the connecting plate 114, up and down in the directions U2 and D2 between two belt structures separated at different height levels with respect to the level of the surface of a moving conveyor belt 26, this also causes, in at least one embodiment, the surface of the formed quartz slab 30a passing above the tie plate 114 to crack, but the crack lines are substantially only in the transverse direction of the moving belts 104 and 110 or to the moving quartz slab 30. Any difference in height may cause the surface of the through slab 30 to crack at the different point of the height, and dye may be sprayed in cracks 16' and 18' at the same time.

Figure 4 shows the lift bars 12 and 14 and the spray bars 20 and 22 in a diagonal orientation with respect to the length of the conveyor belt 26, where the conveyor belt 26 has a width that is substantially less than its length. .

Once the entire formed quartz slab has passed the lifting bar area and the desired area of crack lines created and the dye has been sprayed into the desired section of cracks (turning on and off all nozzles in spray bars 20 and 22 can be controlled separately if necessary), the quartz slab 30 is transferred to a vacuum press. When the press machine is lowered onto the quartz composite material 30, the cracks 16 and 18 (or 16' and 18') sprayed with dye will become lines of the dye in the quartz slab that simulate veins in natural stone in the surface of the slab after the slab 30 has been cured, ground and polished.

Figure 8 shows a simplified block diagram 200 that includes a computer processor 202 and components that communicate with and/or are controlled by the computer processor 202.

Referring to Figure 8, diagram 200 shows a computer processor 202, a computer memory 204, a computer display 206, an interactive computer device 208 (such as a computer mouse, a touch screen or a computer keyboard). computer), and in a simplified block diagram forms, the motor of the conveyor device for the conveyor belt 26, the first servomotor 2, the second servomotor 4, the third servomotor 6, the nozzles 24 and the nozzles 25. The computer processor communicates and controls components 26, 2, 4, 6, 24 and 25, as well as components 204, 206 and 208.

In operation, the computer processor 202 is programmed by computer software stored in the computer memory 204 and/or controlled by the interactive computer device 208 to control the components 26, 2, 4, 6, 24, 25, 24a and 25a.

In one or more embodiments, the spray bars 20 and 22 can be replaced by a human hand with a spray gun, to add randomness by losing part of the crack area, where such randomness may be desired. In other embodiments, a robotic sprayer with a photosensor can replace the spray bars 20 and 22, where the photosensor is used to locate or detect cracks and spray into the cracks as desired. There may be other ways to spray into cracks.

Although the rotation of the lifting bars 12 and 14 is shown in one or more embodiments, driven by the servomotor 4 and controlled by the computer processor 202, in alternative embodiments, the rotation of the lifting bars 12 and 14 can be performed by hand.

Although the up and down movement of Figure 1, of member 7 in Figure 2 is driven by the servomotor 6 and controlled by the computer processor 202 in one or more embodiments, in alternative embodiments, the up and down movement Below member 7 can be implemented manually, such as with a manual jack.

Although the device including the member 3 moves in the directions D1 and D2, in at least one embodiment, as shown in Figure 1, driven by the servomotor 2 and controlled by the computer 202, the member 3 and the fixed components At the same time they can be rotated in the directions D1 and D2, shown in Figure 1, in alternative embodiments by hand.

Figure 9 shows a perspective view of a robotic apparatus 400, a spray or material deposit device 402 and part of the conveyor apparatus 300, including rollers 302, 303, 308 and 309. The conveyor apparatus 300 includes a plurality of tapes 306a-306i, shown in Figure 16, each of which may be parallel to all other tapes of 306a-i. There are grooves in the rollers 302 and 309 to keep the belts aligned during movement. Figure 9 also shows a plate 450, which has a plurality of openings 452. Some of the openings 452, such as opening 452e, shown in Figure 9, are shown with a raised cylinder, and other openings, such as opening 452f, are shown. They are shown without a raised cylinder.

Figure 17 shows a simplified block diagram 500 of a computer processor 502 and components that communicate with and/or are controlled by the computer processor 502. The computer processor 502, the computer memory 504, the display computer 506 and computer interactive device 508 may be similar or identical to components 202, 204, 206 and 208 described above with respect to Figure 8, except as described in this application.

The computer processor 502 may control the conveyor apparatus 300, the robotic apparatus 400 (which may include the spray device 402), and a plurality of cylinders 330. The plurality of cylinders 330 may include an array of a plurality of cylinders corresponding and aligned with the array of a plurality of openings 452. The cylinders 330 may include cylinders 330a-p shown in Figure 12.

The robotic apparatus 400 may be any known robotic apparatus that is controlled by the computer processor 502, according to a computer program stored in the computer memory 504 to move the spray device 502 to any position above the plate 450 and simultaneously within a perimeter of the plate 450, shown in Figure 10, and consequently above the slab 350 and within the perimeter of the slab 350 when the slab 350 overlaps the plate 450 as shown in the Figure 10.

The conveyor apparatus 300 may be controlled by the computer processor 502, as programmed by the computer software stored in the computer memory 504. The cylinders, and specifically the movement of the cylinders up and down, the height of the cylinders or distance, and/or whether a particular cylinder, such as cylinder 330f, protrudes through and above an opening of the plate 450, are controlled by the computer processor 502 as programmed by the stored computer software in computer memory 504.

Each of the cylinders 330a-p may be a solid cylinder. In Figure 12, except for the cylinder 330f, the other cylinders of 330a-p do not protrude above the upper surfaces of the belts 306a-306i, such as the upper surface 307a of the belt 306a. The top surfaces of the tapes 306b-i are typically at the same level of height or distance above the top surface 450a of the plate 450.

If all cylinders 330a-p are below the top surface 307a (and the other top surfaces of the strips 306b-i), then the slab 350 passes over the region of the plate 450, without additional cracks being generated.

However, when a cylinder 330f protrudes above the top surface 307a of the belt 306a (and therefore both above the top surfaces of the tapes 306b-306i), the slab 350 is pushed upward in the direction U1, shown in Figure 12, in that position, to produce one or more cracks in the slab 350.

As shown in Figure 9, there are gaps between the adjacent belts of belts 306a-306i, which allow one or more of the cylinders 452 to protrude through the gaps between the adjacent belts and thus push upward. the slab 350 in direction U1, in particular positions.

In at least one embodiment, the tapes 306a-i are preferably parallel to each other and the spaces between adjacent tapes of the tapes 306a-i preferably have the same width, W1 shown in Figure 10.

In at least one embodiment, the openings 452 shown in Figure 14 are arranged in a matrix with a plurality of rows and a plurality of columns. The distance between adjacent rows of openings 452 is approximately the width W2 of one of the belts 306a-306i, where each of the belts 306a-i typically has the same width W2.

Figure 10 shows a perspective view of the robotic apparatus 400, the spray device 402 and the conveyor apparatus 300, which have been described above, as well as a slab 350 and a sheet 311 that have been moved into position to be processed in part top of plate 450.

Figure 11 shows a front view of the robotic apparatus 400, the spray device 402, the conveyor device or apparatus 300, the slab 350 and the sheet 311 in position to be processed on top of the plate 450. Figure 11 shows the cylinders 330a - 330p, all in lowered state.

Figure 12 shows a front view of the robotic apparatus 400, the spray device 402, the conveyor device or apparatus 300, the slab 350 and the sheet 311 in position to be processed on top of the plate 450. Figure 12 shows the cylinders 330a, 330b, 330c, 330d, 330e, 330f, 330g, 330h, 330i, 330j, 330k, 330l, 330m, 300n, 300o and 330p, with only the cylinder 330f raised so that its front upper edge or upper surface is above the top surface 307a of the tape 306a, and the corresponding top surfaces of the tapes 306b-306i. This causes the sheet 311 and the slab 350 to also rise in the position of the cylinder 330f, causing cracks and fissures to form on the upper surface of the slab 350 above and around the cylinder 330f.

Figure 13 shows a perspective view of the robotic apparatus 400, the spray device 402 and the plate 450. The plate 450 has a plurality of openings 452. Some of the openings 452, such as the opening 452a, are shown darkened to represent a raised cylinder, of the cylinders 330a-p, above the top surface 307a of the belt 306a and above the top surfaces of other belts 306b-i similar or identical to the cylinder 330f shown in Figure 12, and some of the openings 452, such as the opening 452b is not shown obscured to represent a lowered cylinder, similar or identical to what is shown for the cylinders 330a-i except 330f, in Figure 12, which are below the upper surface 307a of the tape 306a and under the top surfaces of the other tapes 306b -306i. Not shown in Figure 13 are the conveying device or apparatus 300, the sheet 311 and the slab 350 that would generally be on top of the plate 450. In this first state of the cylinders 330a-p, the computer processor 502 generates a plurality of raised cylinders to form cracks or fissures in the slab 350 according to a desired final design. Once the cracks or fissures are created, the spray device 402 attached to a robotic arm of the robotic apparatus 400 is controlled by the computer processor 502, as programmed by the computer software in memory 504 to deposit dye or colored material. on top of cracked or fissured area formed. After depositing the dye or colored material, all of the cylinders 330a-p are controlled by the computer processor 502 to return to a lower state, below the upper surfaces of the belts 306a-i.

In at least one embodiment, for the array of the plurality of openings 452 there is an aligned array of a plurality of cylinders corresponding, similar, or identical to the cylinders 330a-p. For example, if there are eight rows and sixteen columns for a rectangular array of apertures 452, then there would be, in at least one embodiment, eight rows and sixteen aligned columns of a rectangular array of cylinders, each cylinder similar or identical to cylinder 330a.

Figure 14 shows a perspective view of the robotic apparatus 400, the spray device 402 and the plate 450 shown in Figure 13. Figure 14 differs from Figure 13 in that different cylinders are raised and therefore show darkened. For example, a cylinder corresponding to the opening 452c rises through the opening 452 and protrudes above the surface 307a of the belt 306a and above the surfaces of the other belts 306b-l, and a cylinder corresponding to the opening 452d does not rise above surface 307a. In the second state, the computer processor 502 produces a different plurality of raised cylinders compared to the first state of Figure 13, to form additional and different cracks or fissures in the slab 350 according to a desired design. Once the cracks or fissures are created, the spray device 402 attached to the robotic arm apparatus 400 is controlled by the computer processor 502 to deposit dye or colored material on top of the cracked or fissured area formed. After depositing the dye or colored material, all cylinders of 330ap, or similar or identical cylinders, are returned to a lowered state by the computer processor 502 below the top surface 307a of the belt 306a and the corresponding top surfaces of the 306b-i tapes.

Figure 15 shows a perspective view of the robotic apparatus 400, the spray device 402 and the plate 450 shown in Figure 13. Figure 15 differs from Figure 13 and Figure 14 in that the different cylinders, of which Cylinders 330a-p are raised, shown darkened. For example, a cylinder corresponding to the opening 452e is elevated above the top surface 307a of the tape 306a and above the top surfaces of the tapes 306b-i and a cylinder corresponding to the opening 452f is not elevated above the upper surface 307a of the tape 306a. In the third state of Figure 15, a different plurality of raised cylinders of the cylinders 330a-p compared to the first and second states, is produced by the computer processor 502 to form additional and different cracks or fissures in the slab 350. according to a desired final design. Once the cracks or fissures are created, the computer processor 502 is programmed to cause the spray device 402 connected to the robotic arm apparatus 400 to deposit dye or colored material onto the formed cracked or fissured area. After depositing the dye or colored material, all cylinders, such as 330a-p, are returned to a lowered state, so that they do not protrude above the top surface 307a of the belt 306a or any of the other top surfaces of the 306b-i tapes.

Figure 16 shows a perspective view of the robotic apparatus 400, the spray device 402, the slab 350, the sheet 311 and the conveyor device 300. The slab 350 has been processed through the first, second and third states above for the cylinders . Lines or veins 360, 361 and 362 are formed during the first, second and third states of the cylinders, respectively.

According to a method in one or more embodiments of the present invention, particulate quartz, resin and other additives are mixed into a wet mixture and distributed uniformly in a mold tray with or without an edge frame. The wet mix is deposited on top of a sheet of paper 311. The length and width of this mix formation or slab 350 can vary.

The wet mix formation or slab 350 is lightly pressed on top by a roller or by a flat plate. This slightly compacts the mixture formation until it reaches a consistency similar to that of moist soil.

The lightly pressed mixture formation or slab 350 is transported through a conveyor apparatus 300, such as by means of belts 306a-i moved by a roller 302 in Figure 9, until the slab 350 overlaps the plate 450, and generally completely within and/or encompassed by the perimeter of the plate 450. The plate 450 has a series of holes or openings 452. This transport action can be achieved in a variety of methods not shown in the figures, such as a device that grabs the sheet 311 and drags it onto the plate 450, and off the plate 450 after it has been processed. Through these holes 452, cylinders, such as cylinders 330a-p, which may be pneumatic, hydraulic, electric or other magnetic cylinders, or the like, can be controlled to rise or fall perpendicular to the plane in the where slab 350 is located. These cylinders 330a-p are controlled by the computer processor 502, shown in Figure 17, and can be lifted independently, with different forces and variable distances. Although only one row of cylinders 330a-p is shown in Figure 12, in at least one embodiment, there would typically be an array of a plurality of rows by a plurality of columns, such that there is one cylinder for each of the openings 452 from plate 450.

By controlling the rise of a certain cylinder or cylinders (or first group of cylinders) of the cylinders 330a-p or similar cylinders corresponding to the matrix of holes 452, through the holes 452 of the plate 450, each cylinder pushes up on the part bottom of the slab 350 through the sheet 311. This causes the upper surface of the mixture formation above the cylinders 330a-p or similar cylinders to crack and fissure. Since the cylinders 330a-p and similar cylinders are controlled by the computer processor 502, according to the computer programming stored in the computer memory 504, the resulting cracks and fissures will have a certain level of controlled randomness. This controlled randomness is desired by design.

Once the pattern of cracks and fissures has formed, a different color of stain or quartz-resin mixture in the form of a liquid, powder, or small particles can be placed, deposited, sprayed, or blended onto the surface of the crack formation. mixture on the cracked areas by means of the spray device 402 of the robotic apparatus 400. The different color of the dye or quartz and the resin mixture in the form of liquid, powder or small particles can be placed, deposited, sprayed, such as by means of the device 402 of the robotic apparatus 400 or in combination, on the surface of the mixture forming on the second pattern of the cracked areas through the control of the computer processor 502. At this point, the first group of cylinders that formed the first pattern of cracks and fissures can be dropped or lowered in height through the control of the computer processor 502.

At this time, the second group of cylinder or cylinders of 330a-p or similar cylinders of a die can be lifted by the control of the computer processor 502, and the second set of corresponding cracks and fissures will be produced on the surface of the formation of mix. The spray device 402 then deposits a different color of dye or quartz-resin mixture in the form of a liquid, powder, or small particles.

The above process can be repeated until the final designed pattern is created.

If necessary, a second color of stain or quartz and resin mixture can be used, which could be different from the 350 slab and different from the first color of the fill material. Spray device 402 can be supplied with solid, liquid, or gaseous material depending on the desired aesthetic. There are a variety of methods for delivering the spray device 402, including, but not limited to, air hoses, tubes, or storage tanks.

The width of the cracks and fissures can be partially controlled by raising the cylinders 330a-p and similar cylinders of a die to varying heights and depositing different amounts of dye or colored material in the cracked areas. This will allow control of the width and depth of the resulting veins.

Once completed, the entire slab 350, as modified, is moved by conveyor apparatus 300 to a heavy-duty vacuum and vibrating press. Once pressed, the slab 350 is transferred to a curing machine. After curing, the slab is trimmed and milled to the desired size, then polished to reveal the finished slab with a grain pattern.

In at least one embodiment, the present invention can elevate certain points of the slab 350 through a series of cylinders 330a-p and similar cylinders of a matrix. A robotic apparatus 400 controls a spray device 402 that deposits or sprays liquid dye, powder or mixture of quartz and resin in particulate form, in any area of the plane in coordination with the group of raised cylinders of cylinders 330a-p

The plurality of cylinders 330 by themselves or in combination with the plate 450 and/or in combination with other components can be considered a device that moves a first part of a slab out of alignment with the majority of the slab and therefore produces a first crack in the slab. The plurality of cylinders 330 and plate 450 may be replaced by physical structures having other shapes, for example, the cylinders 330 may be replaced by a plurality of solid rectangular elements. The plurality of cylinders 330 can be considered a device that applies pressure to a slab in one or more locations. Each of the openings 452 of the plate 452, in at least one embodiment, is circular and has a diameter that is approximately equal to or slightly larger than the diameter of each of the cylinders 330, to allow each of the cylinders to be move upward in the direction U1 through its corresponding opening of the openings 452 and then move downward in the direction opposite to the direction U1, when the particular cylinder of the cylinders 330 retracts.

A variety of methods can be used to control the movement of the spray device 402. In the described embodiment a six-axis robotic arm is used, however, there are many other methods including, but not limited to, gantry frame devices. with spray or delivery device 402 controlled by a computer processor.

In at least one embodiment of the present invention, the cylinders 330 may be elevated beyond the top surface 307a of the belt 306a, except for cylinder 330o (or some other cylinder), which may be lower than the rest of the cylinders. 330 as shown in Figure 18, before placing the slab 350 on top of the cylinders 330. After placing the cylinders 330 in the configuration of Figure 18, the slab 350 can be placed on top of the cylinders 330, simply by dropping the slab 350 onto the cylinders (i.e., the conveyor apparatus 300 cannot be used, nor can any other apparatus be used for transportation). When the slab 350 is dropped onto the cylinders 330, with the cylinders arranged as in Figure 18, cracks C1 and C2 will appear at the location where it is lowered by 330o.

The plurality of cylinders 330 may initially be at their highest height, relative to a floor surface 490. After the slab 350 is lowered onto the plurality of cylinders 330, one or more of the cylinders 330 may be selectively lowered by the computer processor 502 to generate cracks in the slab 350, similar or identical to the cracks C1 and C2 shown in Figure 18.

The floor area 490 is shown in Figures 11, 12 and 18.

Claims (14)

1. An apparatus (1; 100; 400) comprising a first device (12; 114; 330a) that can be actuated vertically to cause a force to be applied to a first part of a slab (30; 30'; 1130; 350) to move vertically out of alignment with an area of the slab that surrounds the first part of the slab and therefore generate a first crack (16; C1) in the first part of the slab (30), where the first device (12; 114; 330a) is configured to be placed between the first part and a ground surface, when the first crack is generated (16; C1); and a device (20, 22; 402) for depositing a material having a color configured to deposit a first material (27) having a color in the first crack (16; C1) of the slab, so that the first crack ( 16; C1) has the first material (27) deposited that becomes a vein that has the color of the first material (27); and further comprising a second device (14; 114; 330b-p) that can be actuated vertically to cause a force to be applied to a second part of the slab (30; 30'; 130; 350) so that it moves vertically out of alignment with an area of the slab (30; 30'; 130; 350) that surrounds the second part of the slab (30; 30'; 130; 350) and therefore produces a second crack (18; C2) in the second part of the slab (30; 30'; 130; 350), where the second device (14; 114; 330b-p) is configured to be located between the second part and a ground surface, when the second part is generated crack (18; C2); wherein the device (20, 22; 402) for depositing a material having a color is configured to deposit a second material (29) having a color in the second crack of the slab (30; 30'; 130; 350) , so that the second crack (18; C2) has the second material (29) deposited becoming a vein that has the color of the second material (29); and characterized in that the apparatus (1; 100; 400) is configured so that while the first device (12; 114; 330a) applies force to the first part to keep the first crack open, the first crack (16; C1) has the first material (27) deposited, wherein the apparatus (1; 100; 400) is configured so that while the second device (14; 114; 330b-p) applies force to the second part to keep the second crack (18; C2) open, the second crack (18; C2) has the second material (29) deposited. 2. The apparatus (1; 100; 400) of claim 1 further comprising a conveyor device (26; 300) that is configured to move in a first direction; and and where the conveyor device (26; 300) is configured to move the slab (30; 30'; 130; 350) over at least a part of the first device (12; 114; 330a), and over at least a part of the second device (14; 114; 330b-p). 3. The apparatus (400) of claim 1 further comprising a plurality of additional devices (330a-p) that are configured to cause a corresponding plurality of additional parts of the slab (350) to move vertically out of alignment with corresponding areas of the slab (350) surrounding the corresponding plurality of parts additional parts of the slab (350) and therefore produce a corresponding plurality of additional cracks in the plurality of additional parts of the slab (350), where each plurality of devices (330a-p) is configured to be located between its corresponding part and the ground surface, when the corresponding crack is generated; and wherein the device (402) for depositing the material having a color is configured to deposit material having a color in the plurality of additional cracks of the slab (350), so that the plurality of additional cracks of the slab are converted into veins that have the color of the particular material deposited. 4. The apparatus (400) of claim 3, wherein the first device (330a) and the plurality of additional devices (330a-p) are arranged in an array of a plurality of rows and columns. 5. The apparatus (400) of claim 1 wherein the first device (300a) is a cylinder. 6. The apparatus (400) of claim 1 wherein the second device (300b-p) is a second cylinder. 7. The apparatus (400) of claim 1 wherein a plurality of said second devices (330b-p) is provided; and where each of the first device (330a) and a plurality of said second devices (330a-p) is a cylinder. 8. The apparatus (1; 100; 400) of claim 1 further comprising a computer processor that controls the movement of the first device, the second device and the depositing device. 9. A method that includes vertically actuating a first device (12; 114; 330a) to cause a force to be applied to a first portion of a slab (30; 30'; 130; 350) to move vertically out of alignment with an area of the slab (30 ; 30'; 130; 350) surrounding the first part of the slab (30; 30'; 130; 350) and thus producing a first crack (16; C1) in the first part of the slab (30; 30' ; 130 ; 350), where the first device (12; 114; 330a) is located between the first part and a ground surface; and depositing a first material (27) that has a color in the first crack (16; C1) of the slab, so that the first crack (16; C1) has the first material (27) deposited, becoming a vein that has the color of the first material (27); and characterized by vertically actuating a second device (14; 114; 330b-p) to cause a force to be applied to a second part of the slab (30; 30'; 130; 350) to move vertically out of alignment with an area of the slab (30; 30'; 130; 350) surrounding the second part of the slab (30; 30'; 130; 350) and thus producing a second crack (18; C2) in the second part of the slab (30; 30'; 130; 350), where the second device (14; 114; 330b-p) is located between the second part and a ground surface; and depositing a second material (29) that has a color in the second crack (18; C2) of the slab (30; 30'; 130; 350), so that the second crack has the second material (29) deposited, becoming in a grain that has the color of the second material (29); where while the first device (12; 114; 330a) applies force to the first part to keep the first crack (16; C1) open, the first crack (16; C1) has the first material (27) deposited; and while the second device (14; 114; 330b-p) applies force to the second part to keep the second crack (18; C2) open, the second crack (18; C2) has the second material deposited. 10. The method of claim 9 further comprising moving the slab (30; 30'; 130; 350) on at least a part of the first device (12; 114; 330a) before causing the first part of the slab (30; 30'; 130; 350) to move vertically out of alignment; and move the slab (30; 30'; 130; 350) onto at least a part of the second device (14; 114; 330b-p) before making the second part of the slab (30; 30'; 130; 350) move vertically out of alignment. 11. The method of claim 9 wherein the first device (330a) is a first cylinder; and The second device (330b-p) is a second cylinder. 12. The method of claim 11 wherein a plurality of said second devices (330bp) is provided. 13. The method of claim 9 wherein a plurality of said second devices (330b-p) is provided; and wherein the first device (330a) and the plurality of second devices (330b-p) are arranged in a matrix of a plurality of rows and columns. 14. The method of claim 9 wherein a computer processor (202; 502) controls the steps to cause the first part of a slab (30; 30'; 130; 350) to move vertically out of alignment with an area of the slab (30; 30'; 130 ; 350); and depositing the first material (27) that has a color in the first crack (16; C1) of the slab (30; 30'; 130; 350).