JP2015057326A - Production and processing of slab - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process and a product improving the problem that chipping of a product in cutting regarding production of a slab and a tile and the breakage thereof occur, and a large quantity of wastes is produced.SOLUTION: Provided is a method for cutting a material slab 2 including cutting a slab 2 using a cutting tool 5 vibrated at the prescribed frequency of ultrasonic waves when material lies in a solidified state. In the method for cutting the material slab 2, the slab material 2 is made of cement, the cement material is installed into a flask 1 and is thereafter cured till it is made into a semi-solidified state, and the semi-solidified state is the one in which the cement material is sufficiently cured so that the slab 2 can be separated without deforming the material during the operation of the cutting tool 5 or after its operation.

Description

  The present invention generally relates to slab products and methods of manufacturing the same.

  Currently, the process of manufacturing cement products, such as tiles, in small individual molds remains substantially the same as the fabrication methods used in the past 50 years and is still prevalent throughout the world.

  However, over the last two decades, the development of tile making has resulted in tiles with a much more modern look in response to the trends and trends in modern architecture and interiors.

  Currently, cement slab products that are commercially available are typically made from a kneaded mixture containing cement, quartz sand, large aggregate pieces (or coarse aggregate pieces), a water reducing agent and water. Large aggregate pieces are included to make up the mass, and their sizes can vary from about 3 mm to 10 mm or larger. Stone chips are often used as large aggregate pieces. The water reducing agent can be a fluidizing agent based on a polycarboxylic acid ether polymer.

  The strength of the materials used to make tiles has improved relatively recently, making it possible to make tiles from a single large thin slab, similar to a marble or granite slab. It can be cut to produce square or rectangular tiles of the desired size.

  Large slabs are formed in individual molds and then subjected to a vibration process. As a result, the finest particles move to the mold bottom. The slab becomes the shape or shape of the surface of the formwork. This is known as a “off-form” material.

  Such a manufacturing method has made it possible to give a wide flexibility to variations in the size and thickness of square and / or rectangular tiles. Cutting tiles from a single slab allows the creation of square and / or rectangular tiles of different sizes, which were previously made in small individual molds. The flexibility in fabrication allows the tiles to be sized as desired by the client, without extensive rework or holding a large number of different sized forms in stock. In addition, it is possible to finish tiles more accurately and better by elaborate machining.

  In addition to the above advantages, cutting large slabs into smaller tiles has the advantage of maintaining the natural aesthetic quality inherent in large types of slabs. When separated, the smaller tiles have a unique appearance that improves the visual impression when large surfaces such as walls and floors are covered with smaller tiles.

  After kneading the material, this material is driven into a large mold and the kneaded product is vibrated on the spot. In the kneading in which the fluid is added to activate the bonding step, the kneaded product is placed on the mold and cured to a sufficient extent that the slab can be removed from the mold. In dry kneading, in which the kneaded product is subjected to heat to start the bonding step, the kneaded product is placed in a mold and pressurized. Dry kneading usually includes a resin with a relatively high melting point, and when sufficient heat is applied, the resin dissolves and bonds the materials remaining during dry kneading together. When the material in the mold is cooled, it becomes a liquid resin and the slab can be taken out of the mold.

  The formwork is typically stored in a location where the material can solidify and cure prior to cutting. The storage period of the wet-kneaded slab is about 1 to 4 weeks until the slab is fully cured and the material is cut.

  In the case of a large slab that has been naturally cured, when it is sufficiently cured, it is demolded, laminated and cured. Offshore can take up to 4 weeks depending on the method and effectiveness of the curing process.

  Of course, in order to allow the slab material to be cured for a sufficient time before the cutting process, it is necessary to move the slab placed from the placement line to the storage area. Generally, the slab remains in the frame after removal from the formwork and is packaged for curing. This involves interrupting the manufacturing process and providing sufficient storage space to store the slab for curing, as well as removing the slab from the formwork and installing it in the storage location for curing. Requires manual intensive process.

  The slab is cut into tiles after calibrating the thickness. After cutting, the tile is “tuned” to create more accurate sides, and the edges of the tile are chamfered or ground to eliminate chipping damage that normally occurs during the cutting process. Thereafter, the individual tiles are subjected to processes such as washing, drying and packing before being shipped for sale.

  The cutting process and subsequent operations are generally performed on a continuous automatic production line.

  As a result, cement or concrete tiles can be juxtaposed and placed in the same way as marble, granite and / or porcelain tiles. Furthermore, the tiles processed in this way generally have a higher quality of installation.

  However, current methods for producing tiles have many significant challenges.

  For example, slab processing (cutting, calibration, edge grinding and / or adjustment) is generally performed using a diamond cutting tool such as a cutting blade, a calibration tool, and the like.

  When cutting a slab, which is a very hard material, the edges of the cut are subjected to various degrees of chipping and become rough edges. Furthermore, slabs and / or tiles are prone to cracking and breaking during the cutting and proofing process. Stress can cause chipping and breakage, especially at the weakest corners of cement slabs or tiles. Chipping, cracking and / or breakage can result in loss or the need to repair damaged material. This can be costly and time consuming.

  Another disadvantage is that processing is difficult and requires care by a skilled operator to improve losses due to chipping, cracking and / or breakage. Such skilled operators are costly and tile production from slabs is time consuming and interrupts the production process.

  After the calibration and cutting steps, the slab product is generally stored again for complete curing, which requires an additional 3 to 4 in a controlled environment before shipping the product to the installation destination. Weekly storage is required. Further storage of slab products for final curing requires additional handling and storage costs.

  Other drawbacks in current fabrication techniques are the need for expensive equipment for cutting (such as diamond tools and large capital equipment), high energy costs (eg electricity), and the process of processing slabs into products There is a lot of water. It is not uncommon for a calibration device to cost over $ 400,000, and including a cutting line is expected to cost about $ 700,000 to $ 1 million.

  The cutting and calibrating processes also result in a large amount of waste that can be generated as material is removed during the cutting and calibrating processes. Therefore, the waste must be separated from the water used for processing before the water is reused. The separated waste must be collected, processed and disposed of, which can be laborious and / or costly. In this regard, the cost of the water filtration system is expected to be approximately $ 100,000 to $ 200,000. Furthermore, since most facilities require a multipurpose power source, the operating cost for the electrical energy consumption of the entire facility is generally enormous.

  When cutting small tiles or mosaic pieces, the cutting process can be particularly lossy because the diamond cutting blade removes 3 to 5 mm of material each time it is cut. When producing many tiles from a slab, the total amount of material removed during the cutting process is enormous.

  Due to problems with existing processes, small tiles, mosaic pieces, and tiles with other shapes other than curved or square are considered too problematic. In the case of mosaic pieces, current production methods typically yield about 40% to 50% yield because about 50% to 60% of the normal material is discarded. This is mainly due to the high rate of damage to the tiles as well as a significant amount of material is discarded as a result of the cutting process to produce relatively small tiles. Unfortunately, the relatively small size of the tiles increases the chipping rate because the tiles move and vibrate when the tiles separate from the slab. Because it is heavy, it does not move much during separation.

  In addition, problems may occur in cutting other types of slab material, such as plasterboard. This is because such materials are generally cut in a hard state after manufacture. Typically, the preparation of a slab and tile production plant is a costly business and requires a lot of planning, preparation, construction and installation time. Factory floors must be specially adapted to accommodate heavy equipment built for specific purposes, and drainage systems for collecting, separating and treating waste from water for each plant And a wastewater tank is needed. In addition to all the above drawbacks, the construction of a factory with a special purpose drainage system itself is very costly and therefore hinders the establishment of a manufacturing facility.

  The tiles produced in the current process have rough edges and / or the appearance of large pieces of aggregate on the side or surface of the tile, such as the production of mosaics, countertops, kitchen islands and / or furniture etc. Not suitable for use. At the present time, it is preferred to use other materials that are considered less problematic for these applications.

  The production of slabs and tiles has at least one further drawback, which is that the product has a high bending force. If the bending force is high, there is a disadvantage that the cracks in the tile cannot be easily seen and may be revealed only after the product is installed in an appropriate place. This may require costly replacement of installed tiles and other products.

  Cracks are not easily visible even when the product is subjected to a strong impact. Such cracks are not easily visible because the intricate structure of coarse aggregate pieces tries to hold the product material together.

  A product that replaces slabs and tiles produced in this way is natural stone. However, natural stone has many variables and is difficult to control. Stone can be inconvenient for certain purposes because it is too soft, too hard, too porous, or too grainy. Furthermore, such materials may not be attractive to customers in terms of aesthetics or may not be suitable for a particular application.

  It is an object of the present invention to provide a process and product that at least ameliorates one or more of the above-mentioned drawbacks associated with slab and tile fabrication.

  References to any prior art (prior art or prior art techniques) cited herein are part of the general knowledge of one of ordinary skill in the relevant arts of the present invention claimed herein. It is not something that recognizes or presents, and should not be considered as such.

  In one aspect, the present invention provides a method for cutting a material slab comprising cutting a slab using a cutting tool that vibrates at a predetermined frequency when the material is in a semi-solid state. .

  In one embodiment, the slab material is cementitious and the constituent materials include cement and other materials whose particle size of the blended mixture is sufficiently small that the material can be cut using a vibration cutting tool. The cement material is placed in the mold, then cured until it is semi-solidified, and when fully cured, it does not deform the material either during or after operation of the cutting tool. The slab can be separated into small pieces (or material removed from the slab) with a cutting tool.

  In one embodiment, the predetermined frequency of the vibration cutting tool is an ultrasonic frequency. This frequency can be adjusted or selected to be optimal for the constituent material of the slab.

  In one embodiment, the cutting tool is a straight blade attached to a robot arm and is maneuvered under the control of a control system that operates the arm. The blades are typically arranged substantially vertically to cut a slab that is arranged substantially horizontally, but such a three-dimensional configuration need not exist between the blade and the slab. For example, the slab may be placed at an angle, and further, the blade may be angled relative to the slab so that the tile can be chamfered or a beveled edge can be created in the tile.

  In another embodiment, the cutting tool is a curved blade that can be used to create a desired profile.

  The cutting tool is not necessarily limited to a blade, and in other embodiments, the cutting tool may include a polishing device or a reciprocating cutting tool for removing a thin layer of material.

  The contour can serve a functional purpose or simply have an aesthetic effect. In this regard, market demand is increasing for new and interestingly shaped floor and wall tiles. In response to the demand for innovative products, high resolution digital printing technology is being used to add complex surface decorations to tiles, and the present invention is the main type currently available. It is particularly suitable to meet the demand for aesthetics different from square and / or rectangular tiles.

  In one embodiment, the slab material is cementitious and the component material does not include large aggregates; otherwise, the large aggregates will be removed from the cutting tool as the cutting tool passes through the material. Prevents passage and / or causes material splitting or waviness. After placing the cement material in the formwork, curing it until it is fully cured, separating the slab into smaller pieces (or removing material from the slab) with a cutting tool And the state of the material does not change after working the cutting tool.

  In another embodiment, the slab is an extruded porcelain. Porcelain slabs may be intended for the production of monocotura (fired once) tiles or bicotura (fired twice) tiles. In this case, any slab material that has been fired twice (or pre-fired) is such that the slab material cannot be cut with a vibration cutting tool in the first firing or baking process performed to reduce the moisture content of the slab. Will not cure until.

  In yet another embodiment of the invention, the slab is a synthetic stone comprising a polyester resin or polymer that acts as a binder to silicic acid or calcareous fine bone materials with physical characteristics similar to those described above. Cutting with an ultrasonic cutting tool such as a straight blade (usually operated with a robotic arm or CNC machine) is performed after pressing and vibration but before heating / curing of the material. In this regard, the material can be cut using one or more vibratory cutting tools and sized and shaped as desired. The dry material is in a semi-solid state of this particular material when in a state after pressurization, and the material is cut in this state.

  Next, the material is placed in a furnace in which the resin binder acts and the dry material binds. When the firing process is complete, the cooled material is a very hard material that can withstand a fairly strong impact.

  In another embodiment, the mold comprises a sacrificial layer of material to absorb the cutting damage that the cutting tool can impart to the mold. The sacrificial layer of material (mold lining) is applied before the material is cast (pressed) into the mold and can be removed after the cutting process when demolding. Mold lining will reduce wear on the mold surface, reduce daily cleaning and / or maintenance requirements, thereby reducing losses and / or costs and / or improving the quality of slab products. .

  In another embodiment, the material includes gypsum. In this embodiment, the slab may further include a liner board. The linerboard may be cut with the semi-solid material to produce a linerboard shape and / or size that is not currently available with current fabrication methods.

  In another aspect, the present invention provides a cutting device comprising a vibration cutting tool and a microprocessor operatively connected to a memory storing instructions. The position of the cutting tool is determined by stored instructions, and the microprocessor executes the stored instructions, thus causing the control system to slab the material in which the vibration cutting tool is in a semi-solid state. Manage to pass.

  In another aspect, the present invention provides an article of manufacture comprising a computer readable medium having stored thereon instructions for controlling a cutting device according to the present invention.

  In another aspect, the present invention provides a slab product according to the method of the present invention.

  It will be appreciated that the term “cure” can be substituted for the term “set”. It will also be appreciated that the term “semi-set” has virtually the same meaning as “semi-plastic” or “semi-hardened”.

It is a perspective view which shows embodiment of the cutting process by this invention. FIG. 3 is a perspective view of a material slab that is cut into a straight line to form an array of square or rectangular tiles when demolding. In this figure, the formwork wall is omitted for explanation. In order to avoid chipping damage to the top surface, or for design purposes, a material slab showing angled cuts carried out by tilting the side wall of the tile and supporting the individual tile on this side wall It is a perspective view. FIG. 3 is a perspective view of a material slab in which the array is cut into a curved shape into an array of circular tiles. FIG. 5 is a cross-sectional view taken along the plane 4B-4B of the slab of FIG. 4 and shows details of the angled cut with the side walls of the circular tile tilted and angled. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention. FIG. 6 is a cross-sectional view of one of various slab products, showing a contour that may be formed using a vibration cutting tool according to embodiments of the present invention.

  It should be noted that all of the following considerations describe specific embodiments, but are exemplary in nature and not limiting.

  The present invention relates to tiles (interior, exterior, floor and wall; conventional and alternative types of tiles); paving coverings for walls (both interior and exterior) mosaics (such as floor mosaics); kitchen bench tops Kitchen counters, kitchen benches, kitchen islands; table tops; integral cast products for tilt-up panels such as scott systems; curtain walls and exterior coverings, optionally with accessories such as products containing fibers; insulation Tiles; other slab products for the slab market; furniture; manufacturing of slabs that can be separated into smaller products such as roof tiles or slabs and / or tiles for other suitable applications.

  An example of a method for producing a slab containing a cement material includes a step of kneading cement, a fine bone material, a fine bone material, and water. The fine bone material and / or the fine bone material may be a siliceous material including sand. Furthermore, the cement kneaded material can also contain osteoclast material and / or powder, and the osteoclast material in this case can be sand.

  In order to reduce the water content of the cement kneaded product, a fluidizing agent having a water reducing action can be added, and the fluidizing agent can be a polycarboxylic acid ether polymer. The amount of fluidizing agent having a water reducing action can be between about 1 and 5% by weight of the cement kneaded product. For example, if the cement content of the cement kneaded product is 100 kilograms, the amount of water-reducing fluidizing agent can be between about 1 kilogram and 5 kilograms. The water-cement ratio when using a fluidizing agent having a water reducing action can be about 0.26.

  The ratio of cement, fine bone material and fine bone material can be 2: 2: 1. For example, a cement mix can include 100 kilograms of cement, 100 kilograms of fine bone material, and 50 kilograms of fine bone material. Further, in an embodiment in which the cement kneaded material includes either a crushed material or a powder, the ratio of cement, fine bone material, fine bone material and crushed sand / powder is 10: 10: 5: 2. Can do. For example, a cement mix can include 100 kilograms of cement, 100 kilograms of fine bone material, 50 kilograms of fine bone material and 20 kilograms of aggregate or powder.

  Of course, the exact material ratio of any kneaded product that will produce optimal results will depend on the quality and suitability of the material, the quality of the polycarboxylic acid admixture and the efficiency of the kneading equipment.

  In yet another embodiment, the cement mix can include vinegar and / or ethanol (buffer), which is included to reduce the air content of the cement mix. The air contained in the cement kneaded product can be in the form of bubbles, and the vinegar and / or ethanol reduces the bubble content of the cement kneaded product. The ratio of vinegar and / or alcohol to cement can be about 0.075.

  The material is kneaded until wet consistency is achieved. The kneading time can be about 3 to 5 minutes.

  After kneading the cement kneaded material, the material is driven into a mold to produce a cement slab. The shape and size of the formwork may vary and may be made from a variety of materials such as aluminum, steel, timber, plastic and / or acrylic. In one embodiment, the formwork is made of glass.

  Since the cutting equipment can damage the surface of the mold, a sacrificial layer of material (or mold liner) can be used with the mold to prevent or at least reduce damage to the mold. The mold liner can be discarded or replaced after the demolding process and is suitable for preventing damage to the formwork surface that may occur when cutting slabs using plastic, wax paper or cutting tools Any material can be used.

  In addition to preventing damage to the mold by the cutting tool, the mold liner also protects the mold surface from the material cast in the mold. In this regard, the mold liner eliminates the need to clean the mold surface after removing the slab product. By eliminating the need to clean the mold surface, there is no time and cost that would otherwise be incurred for this operation. Also, by eliminating damage to the mold surface and the placement of any material, the appearance of the slab product made from the mold remains consistent.

  The cement kneaded product can be self-leveling when in the mold. Self-leveling may take about 2 to 6 minutes continuously as air and air bubbles escape from the cement kneaded product. About 80% to 95% of the air from the kneaded product is expected to escape during the self-leveling process.

  Further reduction of air and air bubbles can be achieved by gently shaking the mold containing the cement kneaded mixture. The cement kneaded product can be vibrated until air and air bubbles do not substantially emerge on the surface of the cement kneaded product. In this regard, the light vibration can be about 3 to 10 seconds. In any case, the degree to which the mixture requires vibration is greatly reduced compared to previous methods of making slabs from cement material. By reducing the degree to which vibration is required, significant variables in the fabrication process are substantially reduced. Naturally, reducing any variable in the manufacturing process has the effect of improving the quality and duplication of the product produced by that process.

  Following leveling and vibration of the cement kneaded product, the cement kneaded product is solidified until it is substantially semi-solidified (or substantially semi-cured). When in the semi-solid state, the cement slab can be cut into tiles or other desired products. In the semi-solid state, the cement material can be cut using a cutting tool such as a knife or sharp tool that vibrates at a predetermined frequency.

  The predetermined frequency can be an ultrasonic frequency, which can be in the range of 20 kHz to 40 kHz. The ultrasonic cutting tool may be handheld or incorporated into an automated machine, such as a computer controlled automatic cutting machine.

  By using a blade that vibrates at an ultrasonic frequency, there should be very little or no cement material sticking to the blade when cutting. This eliminates the need to clean the blade and should eliminate or substantially eliminate the cement material that is removed from the slab during the cutting process. Of course, this also helps to prevent the slab material from splitting, wavy, or deforming without being smoothly separated during the cutting process.

  As shown in FIG. 1, a cement slab (2) can be formed in a mold (1) and can be cut using a cutting tool such as a blade (4) that is compatible with a cutting device (5). The cutting device (5) can be an ultrasonic cutting device.

  The blade (4) cuts the cement slab (2) into a desired shape. In the exemplary embodiment shown in FIG. 1, the cutting part (3) has an irregular shape and a curved shape. Since the slab is cut while in the semi-solid state, the cut (3) may have many different shapes including curved lines and sharp corners. This is particularly useful when a curved shape is required, such as removing a portion from the slab and using it as a kitchen bench top followed by a sink or tapware.

  FIG. 1 also shows various other components of the mold, including the substrate 7, the material layer 9 forming the mold lining, and the mold retaining wall 10. The base 7 must have its surface facing the casting material and is acceptable for use in a mold making a “off-form”. In the embodiment of FIG. 1, the substrate 7 is a glass sheet that has a very uniform surface facing the casting material.

  In order to protect the base 7 from the cutting tool 4, a mold lining 9 is applied to the surface of the base 7. In the embodiment of FIG. 1, the mold lining 9 is applied to the substrate 7 using a tool so that any air between the mold lining 9 and the substrate 7 is substantially removed.

  After the lining 9 is applied, the holding wall 10 is formed. In the embodiment of FIG. 1, the holding wall 10 is formed of a malleable and quick-drying acrylic material. Once set, the wall 10 remains relatively soft and malleable and can be easily removed.

  The ultrasonic cutting tool can be a thin blade capable of cutting a semi-solid cement material. In addition, the material can be cut at a rate of about 4 to 8 meters or more per minute.

  The cement material is cured to a substantially semi-solid state, followed by self-leveling and / or vibration. This curing process portion can be about 30 minutes to 1 hour at room temperature of about 21 degrees Celsius. Higher room temperatures may accelerate the curing time. The cement slab may be cut at any time after the cement material is driven into the formwork, but the cement material must be flattened so that air and / or air bubbles can be discharged and / or removed. It is important to understand that the cement material must be sufficiently cured to be in a semi-solid state.

  For cement material, ensure that the material does not deform and / or fuse together on or around the cut by applying a cutting machine to the cement material and when the material is cut Thus, the suitability for cutting can be evaluated.

  Because cement slabs are cut when in the semi-solid state, the stress on the cement material is substantially reduced compared to previous cutting methods that require the use of a diamond saw blade to cut the hardened material. You will understand. As a result of the reduced stress on the cement material, chipping and breakage of the cement slab should be eliminated or at least substantially reduced. Furthermore, there is substantially no cement material that adheres to the cutting tool in the course of the cutting process of the present invention.

  The cement slab may be cut into tiles of various sizes and shapes. The shape may include a curved shape and a circular shape, and the tile may be made to have a sharp corner.

  FIG. 2 shows a slab without a retaining wall or substrate and mold lining. However, FIG. 2 shows the material slab 12 cut with two longitudinal straight cuts (14 and 16) and a number of transverse straight cuts (18, 20, 22 and 24), the result of which is shown in FIG. The slab 12 is cut into 15 separate square or rectangular tile products.

  Of course, a vibration cutting tool may be used to cut the slab material at an angle rather than substantially perpendicular to the top surface of the slab placed.

  In FIG. 3, the slab 26 without the retaining wall, underlayer or mold lining is again shown. However, FIG. 3 shows a slab 26 having longitudinal cuts (28, 30) and four transverse cuts (31, 32, 33 and 34), each identified longitudinal cut. Two blades of a vibrating knife arranged at an angle with respect to the surface of the slab 26 pass through the part. For example, the cutting section 28 in the longitudinal direction is actually an inverted “V” -shaped cutting section because the blade of the vibrating knife passes through two separate locations. Individual slab products removed from the formwork will have walls that are inclined relative to the surface of the individual slab products. Compared to the individual tiles made from the slab 12 of FIG. 2, the individual tiles made of the slab 26 of FIG. 3 will have walls with sloped edges, which walls are shown in FIG. Compared with tile products made from the above, it has a higher resistance to chipping on the top surface of the tile (the bottom surface of the slabs placed).

  Those skilled in the related art will understand that cutting a semi-solid slab with a vibration cutting tool provides significantly higher flexibility compared to current methods of manufacturing slab products. Will. For example, FIG. 4A shows a slab diagram depicting slab products of various shapes. In this regard, individual slab products have various shapes such as circles, triangles and diamonds. Each of these products can be cut from a slab with inclined walls, and in this particular example, the flexibility provided by the present invention is clearly demonstrated. This is because a variety of different shaped slab products can be produced from a single slab at any point in time, depending on the specific manufacturing requirements.

  Furthermore, the slab 36 shown in FIG. 4A has a slab product that is shaped and structured that is very difficult to manufacture with current manufacturing methods, or at least difficult to manufacture without producing significant amounts of waste. It is included. For example, rhombus tiles are particularly unusual in that it is difficult to cut a rhombus tile from a slab using a diamond saw blade. In this regard, the physical stress applied to the tile in the course of the cutting process using a diamond cutting blade generally results in chipping in the area of the rhombus tile in that the intersection of the tile walls defines an acute angle. It would be very difficult to make rhombus tiles with current production methods because they would cause damage.

  For this reason, a technique for producing curved tiles and / or pointed tiles is to cut a specific desired shape from the slab using a high pressure water jet. However, this approach has a number of disadvantages that make it commercially impractical for making slab products such as tiles. In general, this approach of making tiles is only used for one design where special demands or premium prices are expected.

  As can be seen in FIG. 4A, the degree of flexibility possible for cutting a particular shaped slab product from a slab according to this embodiment of the invention is limited by the ability to control the position and passage of the vibration cutting tool. It is only done. In one embodiment, the vibration cutting tool is controlled by a robotic arm or CNC machine and appropriate controls defining the shape and / or structure of the slab product to be cut from the slab for any particular production requirement. It is only necessary to select a program.

  The control system can determine the path that the cutting tool passes through the slab and can also control the selection of special cutting tools for any region of the slab. The control system includes a microprocessor and a memory device for storing instruction codes for controlling the robot arm. The instruction code can be reliably incorporated into an information carrier such as a CD-ROM, DVD-ROM, semiconductor memory, or hard disk. Such a computer program product can cause a data processing device to perform one or more operations described herein. The memory may encode one or more programs that cause the processor to perform one or more method actions described herein. Further, the subject matter described herein can be implemented using a variety of machines.

  The aspects, features and components selected for the above implementation are described as being stored in memory. However, all or part of the apparatus and / or system may be stored on and distributed over a variety of machines or computer-readable media, including logic circuitry (such as computer-executable instructions) for implementing the method, Or they can be read from. The medium may include a hard disk, a flash memory, a floppy disk, or a storage device such as a future development. The logic circuit can also be encoded into a signal that is transient or not transient, and this signal encodes the logic circuit as it propagates from the source to the destination.

  The logic circuitry that implements the devices and / or systems can include any combination of hardware and software, and both may vary widely depending on the implementation. For example, the processor may be implemented as a microprocessor or microcontroller, DSP, application specific integrated circuit (ASIC), discrete logic circuit, or other type of circuit or combination of logic circuits. Similarly, the memory can be DRAM, SRAM, flash memory or any other type of memory. Device and / or system functionality may be distributed across multiple computer systems. Parameters, databases, and other data structures can be stored and managed separately, can be embedded in a single memory or database, or logically and physically organized in many different ways be able to. Any of the described logic circuits can be implemented as separate programs or distributed to several memory processors using a program that is part of a single program. The logic circuitry can be organized in a software library, such as a dynamic link library (DLL), application programming interface (API), or other library.

  Each slab product defined by slab 36 of FIG. 4A has an inclined wall, which is also shown in FIG. 4B, which is defined by line 4B-4B and slab perpendicular to the top surface of the slab. FIG. 6 is a plan view of a cross section through a plane extending through 36.

  In FIG. 4B, the slab 36 has two circular tiles (38, 40) cut from the slab 36. A circular tile having a circular cut in the slab 36 to define the circular tiles 38 and 40 and having an oscillating cutting blade angled with respect to the top surface of the slab 36 and having an inclined wall from the slab 36. 38 and 40 were cut. The inclined walls of each circular tile 38 and 40 are shown as cuts 42, 44, 46 and 48 in FIG. 4B.

  In addition to cutting tile products of different shapes from highly flexible slabs, the present invention can also produce slab products with various contours in addition to the inclined walls shown in FIGS. 3, 4A and 4B. It becomes possible. In this regard, FIGS. 5A through 5F show the outlines of various slab products.

  FIG. 5A shows a slab product having an inclined wall that has been removed from the slab shown in FIG. 3, and the angle of the inclined wall is about 80 degrees from the horizontal plane. As described above, producing a tile having an inclined wall results in a tile that is more resistant to chipping damage to the tile at the intersection (50) of the wall and the top surface. However, the present invention provides a very high degree of flexibility for the production of tiles or slab products having a desired contour.

  For example, FIG. 5B shows a slab product with one end wall inclined about 45 degrees from the vertical plane. This type of contour is particularly useful for wall tiles where the wall corners are covered with miter-cut edges so that two similarly contoured wall tiles can be adjacent together at the wall corners, This forms the appearance of tiles laid relatively continuously near the corners of the wall.

  In addition, the contour shown in FIG. 5B may be useful when manufacturing a stair tread, in which case the miter cut edge is another slab product with a similar contour that forms a stair lift plate. Used to be adjacent.

  In this regard, it is also possible to generate the contour shown in FIG. 5C according to the present invention, which can also be used for the stair tread, in which case the contour is generally “Bull Nose”. It is said that the safety risk for the user of the stairs is reduced even if the user falls and gives an impact to the rounded surface of the step board of the stairs. Of course, it is preferred to use a vibration cutting device in the form of a round or curved oscillating knife blade in producing the profile shown in FIG. 5C. Furthermore, when creating a contour as shown in FIG. 5C, the vibration cutting tool is reciprocated along the edge of the slab product many times to create the desired contour and removed by passing the cutting tool continuously. It may be necessary to reduce the amount of slab material that is produced.

  FIG. 5D shows the outline of a tile with chamfered edges. Further, FIG. 5E shows tiles with stepped edges, which can be useful and / or produce the desired aesthetic effect. In the case of the contour shown in FIG. 5E, it may be necessary to reciprocate the vibration cutting tool many times along the edge of the slab product, and further to create such an edge contour, It may be necessary to remove the slab material either after the cutting process and provide sufficient usable space to allow the vibration cutting tool to cut the slab material as much as necessary to create the desired contour.

  FIG. 5F shows yet another slab product wheel, in this particular case, the vibration cutting tool is in the form of a cylindrical or substantially cylindrical device, with a sharp edge in this cylindrical or substantially cylindrical shape. It can take the form extending along the periphery of the tubular device.

  For any or all of the contours shown in FIGS. 5A-5F, the width is approximately as desired so that the illustrated contour is produced by cutting the slab product at each edge of the slab product. It may be preferable to create a formwork. This is especially true in the case of the contours shown in FIGS. 5C, 5D, 5E and 5F, where the contours may extend from the top surface of the tile formed as the bottom surface of the cast slab. Desired. In these cases, when the slab is cured until it is semi-solidified, the vibration cutting tool is used to remove the retaining wall formed of malleable acrylic material, expose the edge of the slab material, and the vibration cutting tool is inserted Thus, a desired edge contour can be generated. In one embodiment of the present invention that accomplishes this particular method, the cutting that separates unwanted material from the slab when cutting the mold retaining wall and any excess material and cutting it to form the edge of the slab product. The material to be removed can be removed either during the process or after the cutting process. Removal of the slab material may be accomplished using a robotic arm that steers the cutting device and cutting tool.

  However, in another embodiment of the present invention, when the slab is placed and the initial curing process is started, the top surface of the placement slab can be allowed to be used as the top surface of the slab product by modifying the top surface of the placement slab. Make it look nice. In this regard, the top surface of the cast slab can be rubbed or polished to provide a suitable surface for the slab product. If such a surface is acceptable as the top surface of a slab product, it is somewhat easier to produce the contours shown in FIGS. 5B-5F.

  Cutting the cement slab while in a semi-solid state does not require the use of expensive cutting equipment such as a diamond tool and cuts the cutting time. Also, the amount of water required for cutting can be substantially reduced or eliminated entirely. This has the new advantage that little or no wastewater has been produced that previously required costly treatment and / or disposal.

  Cutting the cement slab while in a substantially semi-solid state significantly reduces energy consumption compared to previous cutting methods. Many of the above advantages can also lead to reduced manufacturing costs. This is especially true in the case of mosaic tiles (ie, tiles with relatively small dimensions). Currently, the loss that occurs when cutting a mosaic tile from a slab using a diamond saw blade is enormous. As a result, mosaic tiles have a premium price. This is because the percentage of loss that occurs during the fabrication process using currently accepted methods can range from 50% to 60% due to damage in the fabrication process and the material removed by the saw blade. is there. Mosaic tiles are rarely used in building construction, as the average yield for making mosaic tiles is between 40% and 50%, as mosaic tiles are given exceptional prices.

  Of course, making mosaic tiles using the systems and methods of the present invention is virtually lossless (or at least substantially lossless) compared to cutting a zyctile from a slab using a diamond saw blade. (Higher output).

  A cement slab may be cast to produce a slab product having a thickness of about 3 mm to 6 mm. This has the potential to create new and innovative products.

  Further, the material can be substantially strengthened as a result of less stress on the product during the processing. Similarly, this can reduce problems such as breakage of corners during product installation.

  In addition, since a large aggregate piece is not used for producing a cement material, there is a possibility that problems after installation related to slow progress of cracks (hairline cracks, etc.) may be reduced.

  The fine material and / or fine material may comprise limestone, granite or marble. The cement mix may include some or all combinations of these materials or other siliceous materials.

  Thickness consistency can also be evaluated and / or calibrated for cement slabs. Any area of the cement slab that is thicker (higher) than desired can be removed. Removal can be performed with a cheese grated type device that acts as a cutting tool. However, any requirement to evaluate and / or calibrate the thickness of the cement slab and / or remove material from the thicker slab area is substantially minimized by the method of making a slab according to the present invention. You will see that it should be done or gone.

  To flatten the thickness, evaluating and / or calibrating the thickness and / or removing the cement material can be done before or after cutting the slab into tiles. However, the evaluation and / or removal of the cement material is performed while the cement slab is in a semi-cured (semi-solidified) state, thereby reducing the stress experienced by the product compared to the cured product.

  After cutting the cement slab, the tile is stored for about 20 to 24 hours, thereby further curing the product, such as a tile. As the tile hardens, it can be removed from the formwork.

  In an alternative embodiment, the present invention can be used to make a plasterboard. In this embodiment, the plasterboard can be produced in the mold, in which case the first surface of the linerboard of the plasterboard is placed in the mold and the plaster material (such as plaster) is the first liner in the mold. The second side of the plasterboard liner board is then placed on the plaster material to form a “sandwich” that sandwiches the plaster material between the liner boards.

  Next, the plaster board is cut using a blade that vibrates at a predetermined frequency while the plaster material is in a semi-solid state. The blade also cuts the first side and the second side of the linerboard.

  In this way, it is also possible to form plasterboards of various shapes, and if the plasterboard is cut when the plaster material is completely or substantially completely solidified, it is not possible to form these shapes. Practically even more difficult

  The present invention embodies various advantages and, in particular, enables the manufacture of slab products that are efficient and low cost compared to existing processes. For example, by cutting a semi-solidified slab material, it is not necessary to harden the slab to the extent that it can sufficiently withstand the stress and impact when cutting the slab using a diamond blade. This eliminates the need to intervene in the processing of the slab from casting to cutting, and eliminates the need for expensive equipment for kneading and calibration / cutting that is normally used in current manufacturing processes. There are double advantages.

  In addition, the manufacturing process must use water to capture and remove excess material from the cut surface by reducing or virtually eliminating the amount of material removed from the slab during the cutting process. Disappear. This also eliminates the need for water filtration equipment and the ongoing maintenance usually required for such systems.

  By eliminating the need for large heavy equipment or for drainage and treatment systems, it is no longer necessary to produce slab products in specially constructed facilities. In contrast, the production of a slab product according to the invention can be carried out in any facility that can accommodate the equipment necessary to achieve a semi-solid cutting of the slab material. In this regard, the power consumption for operating such equipment is substantially less than what is currently required. In addition, by enabling the cutting process to be performed immediately after the placing process, there is no intensive manual operation caused by temporarily storing the slab for curing, and the slab can be cut until it can be cut. There is no need for storage.

  One skilled in the art will appreciate that the above method can be applied in making material slabs other than cement slabs or plasterboards.

  While several exemplary embodiments have been described, such embodiments are merely illustrative and are not intended to limit the invention, and the invention is not limited to the specific designs and configurations described herein. It should be understood that the invention is not limited to. This is because various other changes, combinations, omissions, corrections and replacements are possible in addition to those described in the above paragraph. Those skilled in the art will recognize that various adaptations and modifications of the above embodiments can be made without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Claims (23)

  A method of cutting a material slab, comprising cutting the slab with a cutting tool that vibrates at a predetermined frequency when the material is in a semi-solid state.   The slab material is cementitious and the constituent material includes cement and other materials whose particle size of the blended mixture is small enough to cut the material using a vibration cutting tool. the method of.   The cement material is placed in a mold and then cured until it is in a semi-solid state, which is without deformation of the material either during or after operation of the cutting tool, The method according to claim 2, wherein the slab is sufficiently cured to be separated by the cutting tool.   The slab material is not cementitious and the components after kneading are relatively dry and the mixture is placed in a mold to bring the material into a semi-solid state prior to cutting the slab. The method of claim 1, wherein the method is pressurized and heated.   The slab material is gypsum, the gypsum slab material is lined with a cellulose material, and both are cut using the cutting tool while the gypsum material is in a semi-solid state. The method described in 1.   The method according to claim 1, wherein the predetermined frequency of the vibration cutting tool is an ultrasonic frequency.   The method according to claim 1, wherein the frequency can be selected to be optimal for the constituent material of the slab.   The method according to claim 1, wherein the cutting tool is a blade.   The method according to claim 1, wherein the cutting tool is a curved blade.   The cutting tool is maneuvered under the control of a control system comprising a microprocessor and a memory for storing instructions, so that the position and movement of the cutting tool depends on the stored instructions executed by the microprocessor. 10. A method according to any one of claims 1 to 9, which is determined.   The slab material in a semi-solid state is disposed substantially horizontally, and the cutting tool includes a control system such that the vibrating blade passes through the slab material and cuts the slab material at a desired position. The method according to claim 1, wherein the method is a straight blade that is steered under control.   12. A method according to claim 10 or 11, wherein the blades are arranged at an angle rather than perpendicular to the surface of the material slab, so that portions of the slab can be separated by angled cuts. .   A plurality of cutting tools are used in cutting a material slab, the most appropriate cutting tool being selected according to the cutting requirements for a specific range of the material slab. The method according to item.   14. A method according to any one of the preceding claims, wherein cutting the material slab comprises removing a thin material layer from any one or more surfaces of the material slab.   The slab material is cementitious, and the formwork is formed from a base coated with a malleable material, thereby forming a formwork wall to hold the slab material placed in the formwork. The method according to claim 1, wherein the malleable material can be cut by the vibration cutting tool in a process of cutting the slab material in a semi-solid state.   A slab product separated from a material slab by the method according to any one of claims 1-15.   A vibration cutting tool, a microprocessor, and a memory operatively connected to the microprocessor for storing instructions, the position of the cutting tool is determined by the stored instructions, and the microprocessor is configured to store the stored instructions A cutting device for controlling the control system to pass the oscillating cutting tool through a semi-solidified material slab.   The cutting apparatus according to claim 17, wherein the control system selects a frequency of the cutting tool.   19. The cutting device according to claim 18, wherein the control system selects an ultrasonic frequency for vibrating the cutting tool.   19. The cutting device of claim 18, wherein the control system is operable to select an optimal frequency for cutting the material slab.   21. A cutting device according to any one of claims 17 to 20, wherein the control system is operable to be selected from a plurality of cutting tools including straight blades and curved blades.   22. A cutting device according to any one of claims 17 to 21, wherein the cutting tool is operable to cut a material slab at an angle rather than perpendicular to the surface of the slab.   23. A product comprising a computer readable medium, wherein instructions for controlling the cutting device according to any one of claims 17 to 22 are stored in the medium.

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