WO2011006194A1 - Mixture of slab production - Google Patents
Mixture of slab production Download PDFInfo
- Publication number
- WO2011006194A1 WO2011006194A1 PCT/AU2010/000889 AU2010000889W WO2011006194A1 WO 2011006194 A1 WO2011006194 A1 WO 2011006194A1 AU 2010000889 W AU2010000889 W AU 2010000889W WO 2011006194 A1 WO2011006194 A1 WO 2011006194A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould
- slab
- mixture
- cementitious
- cut
- Prior art date
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
- B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/05—Stirrers
- B01F27/11—Stirrers characterised by the configuration of the stirrers
- B01F27/112—Stirrers characterised by the configuration of the stirrers with arms, paddles, vanes or blades
- B01F27/1124—Stirrers characterised by the configuration of the stirrers with arms, paddles, vanes or blades rake-shaped or grid-shaped
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/05—Stirrers
- B01F27/11—Stirrers characterised by the configuration of the stirrers
- B01F27/13—Openwork frame or cage stirrers not provided for in other groups of this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
- B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
- B01F27/805—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis wherein the stirrers or the receptacles are moved in order to bring them into operative position; Means for fixing the receptacle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/12—Apparatus or processes for treating or working the shaped or preshaped articles for removing parts of the articles by cutting
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/02—Selection of the hardening environment
Definitions
- the present invention relates generally to slab products and methods of manufacturing same.
- cementitious slab products are produced from a mix which typically comprises cement, silica sand, large (or coarse) aggregate pieces, a water reducing admixture and water.
- the large aggregate pieces are included to make up mass and may vary in size from approximately 3mm to 10mm or larger. Stone chips are often used as large aggregate pieces.
- the water reducing admixture may be a plasticizer based on Polycarboxylatic Ether Polymer.
- the strength of material used in tile production has increased in relatively recent times, allowing tiles to be produced from a single large and thin slab, similar to marble or granite slabs, which can be cut to produce square or rectangular tiles of a desired size.
- a slab takes the form or shape of the surface of the mould. This is known as "off-form" material.
- the material After the material is mixed it is placed into large moulds where the mix is vibrated into place.
- the mix For mixes where fluid is added in order to activate the bonding process, the mix is poured into the mould and allowed to cure to a sufficient extent to allow the slab to be removed from the mould.
- the mix For dry mixes where the bonding process is commenced by subjecting the mix to heat, the mix is poured and pressed into the mould. Dry mixes usually include resins that have a relatively high melting point and once sufficient heat is applied, the resin melts and bonds the remaining materials in the dry mix together. Cooling the material in the mould then sets the liquefied resin and allows the slab to be extracted from the mould.
- the moulds are generally stored in a location where the material is allowed to set and harden prior to cutting.
- the storage period for wet mixed slabs is approximately one to four weeks before the slab is sufficiently cured for cutting of the material.
- Curing may require up to 4 weeks depending on the method and effectiveness of the curing process.
- the need to allow the slab material sufficient time to cure prior to the cutting process requires the poured slabs to be shifted from the pouring line to a storage area.
- the slabs rest on frames after removal from their mould and are packaged for curing. This requires an interruption to the manufacturing process and the provision of sufficient storage space to store the slabs for curing in addition to the manually intensive processes associated with the removal of the slabs from their moulds and placing into storage for curing.
- Slabs are calibrated for thickness before being cut into tiles. Following cutting, tiles are "rectified" to produce more accurate sides, the edges of the tiles are chamfered or arrised to erase chipping damage that is usually caused during the cutting process. Individual tiles are then processed including cleaning, drying and packing before being dispatched for sale.
- the cutting process and subsequent operations are commonly performed on a continuous automated production line.
- cement or concrete tiles may be ordered and installed in a similar manner to marble, granite and/or porcelain tiles. Further, tiles processed in this manner generally result in a higher quality installation outcome.
- the processing (cutting, calibrating, arising and/or rectification) of a slab is generally effected by use of diamond cutting tools, such as cutting blades, calibrating tools etc.
- diamond cutting tools such as cutting blades, calibrating tools etc.
- the edges of the cut are subject to varying degrees of chipping and rough edges.
- the slabs and/or tiles are liable to crack or break during the cutting and calibrating process. The stresses can cause chips and breakages, particularly at corners where the cementitious slab or the tiles are weakest. The chipping, cracking and/or breakages can result in wastage or the need to repair damaged material. This can be both costly and time consuming.
- Another disadvantage is that the processing is difficult and requires care by skilled operators in order to ameliorate wastage due to chips, cracks and/or breakages. Such skilled operators are costly and the production of the tiles from the slab is time consuming and interrupts the production process.
- the slab products are generally stored again to fully cure which may require a further three to four weeks of storage in a controlled environment before dispatching the products to their installation destination.
- the further storage of slab products for final curing represents additional handling and storage costs.
- the operational cost with respect to electrical energy consumption of all the equipment is generally significant as most of the equipment needs a multipurpose power supply.
- the cutting process can be particularly wasteful when cutting small tiles or mosaic pieces as the diamond cutting blade removes approximately 3mm to 5mm of material from each cut.
- the total volume of material removed during the cutting process is significant.
- it has been considered that producing small tiles, mosaic pieces and tiles with curved or other non-quadrangular shapes is too problematic.
- present production methods typically result in approximately 50% to 60% wastage of material thereby only generating a 40% to 50% yield.
- Tiles produced by present processes are not suitable for applications such as creating mosaics, countertops, kitchen islands and/or furniture etc due to the rough edges and/or appearance of the large aggregate pieces at the sides or at the surface of the tiles.
- the high flexural strength has the disadvantage that cracks in the tiles do not appear readily and may only become obvious after the product has been fixed in place. This may lead to the requirement for expensive replacement of products such as installed tiles.
- natural stone material An alternative product to slabs and tiles produced therefrom is natural stone material.
- natural stone material has many variables which are difficult to control.
- the stone material may be too soft, too hard, too porous or may have too many veins to be useful for a particular purpose.
- such materials may not be aesthetically appealing for a customer or suitable for a particular application.
- the present invention provides a method for producing a cementitious slab including mixing together cement with other materials with the combined mixture of materials having physical particle sizes sufficiently small to allow the material to be cut with a vibrating cutting tool when the material is in a semi-set state.
- the mix may include fine and ultra fine aggregate material and a water reducing plasticizer, which may be a polycarboxylic ether polymer. Further, the mix may also include at least one of a crushed aggregate material or flour and water.
- a buffer solution is added to the mixture to reduce surface tension.
- one or more of vinegar and/or ethanol is added to the mixture which has the effect of reducing air contained in the mix.
- other fluids may be added for this purpose.
- a buffer solution to reduce surface tension in the mix allows the material to be poured into a mould and for the poured material to release any entrapped air within the mixture without requiring vigorous vibration that is presently needed to agitate material to allow entrapped air to rise to the surface and escape the mixture prior to curing.
- a water reducing plasticiser such as a polycarboxylic ether polymer has the effect of reducing the viscosity of the mixture such that it can "self level” and to a certain extent "self compact”.
- the fine aggregate material and/or an ultra fine aggregate material and/or the crushed aggregate (flour) material is a siliceous material.
- the siliceous material is sand (silica sand).
- the material is mixed together thoroughly.
- the mixing may be performed with a standard commercial dough mixer (or similar device). This avoids the need for an extensive planetary mixer that is usually required when mixing cementitious materials, containing large aggregates and also assists to effect a more thorough mix of the materials.
- the material may be poured into a mould.
- a mould is formed by creating retaining walls on a flat surface. The walls of the mould are prepared specifically for each pour of the material.
- the flat surface is a pane, or sheet, of glass and the mould walls are formed with a quick drying acrylic material that is ejected under pressure from a container.
- the acrylic material is a material commonly used for filling gaps prior to painting a surface. Further, the material is ejected from the container and directed toward a removable mould forming wall that retains the acrylic material in place until it is sufficiently dry to remove the forming wall. The acrylic material is allowed to cure sufficiently until it is capable of retaining the poured material within the mould walls.
- the present invention enables mould walls to be formed with quick drying acrylic material as there is a reduced requirement for vigorous shaking and/or vibrating in order to level the material and cause entrapped air to escape. Ordinarily, mould walls formed with a malleable acrylic material would not be sufficiently strong to retain the poured material during a shaking or vibrating process.
- the mould may include a sacrificial layer (or mould liner) that is applied prior to pouring the material into the mould and may be removed when de-moulding occurs.
- the mould lining may be a relatively thin sheet of plastic material and in one embodiment, the mould liner is applied to the mould surface with a device to reduce the likelihood of air being entrapped between the mould surface and the mould liner.
- a mould liner reduces wear on the mould surface in addition to substantially reducing the requirement for daily cleaning and/or maintenance therefore reducing wastage and/or costs and/or improving quality of the slab product.
- the fine aggregate material may be sized between approximately 355 microns and 700 microns, the ultrafine aggregate material may be sized less than 355 microns and the crushed aggregate material and/or flour may be sized less than 150 microns.
- the sizes of the particles described above have been found to allow a cementitious slab to be cut in a semi-set state without the material tearing or rippling either during or after the cutting process or melding back together once cut.
- the slab further includes a colouring agent that is added to the mixture.
- materials are added to the mixture to provide the slab and/or any slab products separated therefrom with properties that are otherwise unknown for present slab products.
- the present invention allows relatively thin slabs 3.5mm to 5mm) to be manufactured as they retain the necessary structural integrity despite their reduced thickness.
- material such as nano titanium dioxide
- nano titanium dioxide is a photocatalytic agent that is presently added to paint such that painted surfaces display the desired properties of the photocatalytic agent, namely, the breakdown of airborne pollutants and removal of same from the atmosphere.
- nano titanium dioxide is relatively expensive and it is presently only used in materials that are applied to surfaces as a thin layer. This enables the surface to embody the desired property of the photocatalytic agent at a reasonable cost.
- Cementitious slabs are generally manufactured with a significantly greater thickness to provide the required strengths and as a result, adding sufficient quantities of expensive material such as a photocatalytic agent is commercially infeasible as the amount required in the slab to render an outer surface with the desired properties results in an excessive cost of the slab products.
- aggregate such as limestone or marble chips can be used where the particle size is reduced sufficiently to allow a poured slab to be cut in a semi-set state without the slab deforming either during or subsequent to the cutting process.
- an aggregate that doesn't exhibit a propensity to absorb water.
- water bleed or "fine particle bleed” occurs where the water carries fine particles away from a cut surface and it is difficult to cut with a vibrating cutting tool without the material deforming and re-joining around the cut. Accordingly, some aggregate materials will provide a better result for subsequent cutting of the material as compared with others.
- the material may be cut in a semi-set state prior to fully curing. Again, this is enabled as a result of the choice of materials in the mixture and further reduces stress that would otherwise be imparted to a slab during the cutting process.
- the slab is cut with a vibrating cutting tool, which is another contributing factor that enables cementitious slabs to be manufactured with a reduced thickness as compared with present production techniques.
- Fig. 1 is a diagrammatic illustration of a mixing vessel containing the component parts of a mixture prior to the mixing process
- Fig. 2 is a diagrammatic illustration of a mould substrate and a mould liner prior to fitting
- Fig. 3 is a diagrammatic illustration of a mould substrate and a mould liner during the fitting of same;
- Fig. 4 is a diagrammatic illustration of the application of mould retaining walls to a substrate to which a mould liner has been fitted
- Fig. 5 is a diagrammatic illustration of pouring a mixture into a mould
- Fig. 6 is a diagrammatic illustration of a slab of material in a mould in a semi-set state during a cutting process
- Fig. 7 is a diagrammatic illustration of the slab products resulting from the cutting process illustrated in Fig. 6 with the mould retaining walls removed and the slab products de-moulded;
- Figs. 8A and 8B illustrate respectively the representative appearance of a prior art slab of material at a cut edge and a slab of material according to an embodiment of the invention.
- Figs. 9A and 9B diagrammatically illustrate de-moulded slab products with the mould lining removed and retained fitted to the slab product respectively.
- the present invention is relevant to the manufacture of cementitious slabs and/or tiles produced therefrom, which may be used for tiles (internal, external, floor and wall; conventional and alternative type tiles); paving cladding for walls (both internally and externally) mosaics (including floor mosaics); kitchen bench tops; kitchen counters, benches and islands; table tops; integrally cast products for tilt-up panels, including scott systems; curtain walling and external cladding with optional accessories, including products containing fibre; insulation tiles; other slab products for the slab market; furniture; roof tiles or slab and/or tiles for other suitable applications.
- tiles internal, external, floor and wall; conventional and alternative type tiles
- kitchen bench tops kitchen counters, benches and islands
- table tops integrally cast products for tilt-up panels, including scott systems
- curtain walling and external cladding with optional accessories including products containing fibre; insulation tiles; other slab products for the slab market; furniture; roof tiles or slab and/
- An example method for producing a cementitious slab according to the present invention includes steps of mixing cement, a fine aggregate material, an ultra fine aggregate material and water.
- a mixing vessel (10) is illustrated containing materials such as cement (12), fine aggregate (14) an ultra-fine aggregate (16) and a crushed or ground (flour) material (17).
- the mixing vessel (10) is also illustrated containing three mounds of pigment (18) that are included in the mix to achieve the desired colour of the resulting slab of material.
- the fine aggregate material (14) and/or the ultra fine aggregate material (16) and/or the crushed or ground (flour) material (17) may be a siliceous material, including sand. Further, the cementitious mix may also include a crushed aggregate material and/or flour, wherein the crushed aggregate material may also be sand.
- a water reducing plasticizer may be added, which may be a polycarboxylic ether polymer.
- the amount of water reducing plasticizer may be between approximately 1% to 5% of the mix by weight of cement.
- the amount of water reducing plasticizer may be between approximately 1 kilogram and 5 kilograms.
- the water to cement ratio, where a water reducing plasticizer is used, may be approximately 0.24 to 0.26.
- the ratio of cement (12) to fine aggregate material (14) to ultra fine aggregate material (16) may be 2:2:1.
- the cementitious mix may contain 100 kilograms of cement, 100 kilograms of fine aggregate material and 50 kilograms of ultra fine aggregate material.
- the ratio of cement to fine aggregate material to ultra fine aggregate material to crushed sand or flour may be 10:10:5:2.
- the cementitious mix may contain 100 kilograms of cement, 100 kilograms of fine aggregate material, 50 kilograms of ultra fine aggregate material and 20 kilograms of crushed aggregate material or flour.
- the precise ratios of materials in any mix that will produce the best result will depend upon the quality and suitability of the materials, the quality of any polycarboxylate admixture and the efficiency of the mixing apparatus.
- a buffer solution is added to the cementitious mix to reduce surface tension such as vinegar and/or ethanol, which is included in order to reduce air content of the cementitious mix.
- the air content of the cementitious mix is generally in the form of air bubbles and it is intended for the vinegar and/or ethanol to reduce the air bubble content of the cementitious mix.
- the vinegar and/or alcohol to cement ratio may be approximately 0.075.
- the cementitious mix may be mixed in a standard commercial dough mixer including a mixing vessel (10) and a mixing head (20) until thoroughly mixed into a wet consistency.
- the period of mixing may be approximately 3 to 5 minutes.
- a mould substrate (24) is provided in the form of a sheet of glass.
- a suitably sized sheet of mould liner (26) is removed from a roll of the liner material (28) and placed over the mould substrate (24).
- the liner (26) is then applied to the top surface of the mould substrate (24) as illustrated in Fig. 3.
- the liner (26) is applied to the substrate (24) firmly in order to prevent, or at least minimize, the possibility of air being trapped between the liner (26) and the mould substrate (24)
- mould liner (26) is applied to the mould substrate (24)
- an acrylic material is dispensed from a tubular container (28) to form a mould retaining wall (3D) (refer Fig. 4).
- the height of the mould retaining wall (3D) will depend upon the required depth of the slab.
- slab material (32) is poured into the mould from a mixing vessel (34).
- Moulds may be of varying shapes and sizes and may be made from various materials including aluminium, steel, timber, plastic, glass and/or acrylic etc.
- the mould lining assists in preventing damage to the mould by the cutting tool and may discarded and replaced after the de-moulding process.
- the mould liner may be formed from plastic, waxed paper or any material suitable for this process.
- the cementitious mix is allowed to substantially self-level.
- the self-leveling process may require approximately 2 minutes to 6 minutes in duration.
- air and air bubbles escape from the cementitious mix. Approximately 80% to 95% or greater of air and air bubbles are expected to escape from the mix during the self- leveling process without intervention.
- a further reduction in air and air bubbles may be achieved by gently vibrating the mould containing the cementitious mix.
- a cementitious mix may be vibrated until air and air bubbles substantially no longer appear to be escaping the surface of the cementitious mix.
- the gentle vibration may be of approximately 3 to 10 seconds duration.
- the cementitious material or cementitious slab is cut in to tiles or other desired products.
- the cementitious material may be cut with a knife or other sharp cutting tool vibrated at a preselected frequency.
- the preselected frequency may be an ultrasonic frequency, which may be in the range of 20 kHz to 40 kHz.
- the ultrasonic cutting tool may be a hand held type or may be incorporated into automated machinery, such as computer controlled automated cutting machinery.
- an embodiment using a blade vibrating at an ultrasonic frequency should result in very little or substantially no cementitious material adhering to the blade when cutting. This should result in the blade not requiring cleaning and should also result in little or substantially no cementitious material being removed from the slab during the cutting process.
- a diagrammatic illustration of the cutting process is provided wherein the slab material (32) has cured to a semi-set state and a cutting device (36) controlled by a robotic arm passes a vibrating cutting tool (38) through the slab material (32). A path 40 is cut through the slab material (32).
- a diagrammatic illustration of the slab products (42, 44) resulting from the cut 40 through the slab of material is provided. Further, in Fig. 7, the mould retaining walls (3D) have been removed and this can be effected by trimming the mould retaining walls (3D) off the slab. In this regard, selecting a material for the mould retaining wall
- the ultrasonic cutting tool (38) may be a thin blade, capable of cutting but substantially not removing cementitious material from the slab. Further, cutting of the material may occur at a rate of approximately 300 to 800mm per second. It should be understood that, when the cementitious slab is in a semi- set state, other cutting techniques may be employed as an alternative to ultrasonic cutting.
- the cementitious material may cure into a substantially semi-set state following self-leveling and/or vibration. This part of the curing process may be approximately 30 minutes to 1 hour in an ambient temperature of approximately 21 degrees Celsius. A higher ambient temperature may accelerate the curing time. It is important to understand that cutting of the cementitious slab may occur at any time after the placement of the cementitious material into a mould, however, the cementitious material should be leveled and, air allowed to escape or be removed with further time allowed for the cementitious material to sufficiently cured so as to be in a semi-set state.
- the cementitious material may be assessed for suitability for cutting by applying the cutter to the cementitious material and observing that when the material is cut it substantially does not move and/or meld back together over the cut.
- the cementitious slab may be cut into tiles having a range of sizes and shapes.
- the shapes may include curved and rounded shapes and the tiles may also be produced with sharp corners.
- cutting a cementitious slab whilst in a semi-set state does not require the use of expensive cutting equipment, such as diamond tools, and reduces cutting time. Also, the amount of water required for cutting is substantially reduced or may be eliminated altogether. This has a further advantage in that little or no effluence is produced, which previously required expensive treatment and/or disposal.
- the method of the present invention may be used to prepare a slab material from which it is possible to cut shapes, angles and sizes which have previously been considered as either not possible or too problematic.
- the cementitious slab may be poured to thicknesses of between approximately 3mm to 5mm and subsequently cut into slab products which may create possibilities for new and innovative products.
- the material may be substantially stronger.
- the strength of the material is further enhanced by the use of flour materials and an emphasis upon reduction of the water content of the slab mixture. In turn, this may result in fewer problems, such as broken corners etc, during installation of the product.
- Fig. 8A an example profile of a cut edge of a slab product according to present production methods is illustrated in which the size and shape of the large aggregate dominates the appearance. This appearance has had a limiting effect when considering whether or not to use existing slab products for various applications.
- Fig 8B illustrates an example profile of a cut edge of a slab product according to the present invention which is expected to be more widely accepted for use in instances where the cut edge will be visible.
- the cementitious slab may also be assessed and/or calibrated for consistency of thickness whilst in a semi-set state. Any areas of the cementitious slab which are thicker (higher) than desired may be removed.
- Removal may be effected by a cheese grater type device.
- any requirement for assessing and/or calibrating the thickness of the cementitious slab and/or removing material from thicker areas of the slab should be substantially minimised due to the method of production of the slab according to the present invention.
- Assessing and/or calibrating the thickness and/or removing cementitious material in order to achieve an even thickness may occur before the slab is cut or after the slab is cut into tiles. However, calibration and/or assessing and/or removing cementitious material should occur whilst the cementitious slab is in a semi-hardened (semi-set) state.
- the tiles are stored for approximately 20 to 24 hours, which allows for further hardening of the tiles.
- the tiles are hardened such that they may be taken from the mould.
- the de-moulded tiles are then packaged and allowed to completely cure.
- Figs. 9A and 9B de-moulded slab products are illustrated.
- the mould liner has been removed from the slab product (46). This may occur at the time of de-moulding where the slab product (46) is removed whilst the liner is retained in place.
- the mould liner is cut at the time the slab product is cut and thus the liner (50) remains attached to the slab product (48) subsequent to de-moulding. The liner (50) may then be removed from the slab product (48) or retained in place to protect the slab product (48) during subsequent handling and transport.
- the present invention embodies various advantages and in particular, enables the efficient and less costly manufacture of slab products as compared with existing processes.
- the cutting of slab material in a semi-set state avoids the need to allow the slab to harden to a sufficient extent to withstand the stress and impact of cutting the slab with a diamond tipped blade.
- This has the combined advantages of avoiding the requirement to interrupt the processing of the slab between pouring and cutting and obviates the need for expensive mixing and calibrating / cutting equipment that is normally used in present day manufacturing processes.
- the manufacturing process avoids any need to use water to capture and carry the excess material away from the cutting surface. This avoids any requirement for a water filtration plant and the on-going maintenance that is usually required for such a system.
- manufacturing slab products in accordance with the present invention may be performed in any facility capable of housing the necessary equipment to effect cutting of slab material in a semi-set state.
- the electrical power consumption to operate such equipment is substantially less than present requirements.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Civil Engineering (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
- Milling Processes (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP10799277.8A EP2593281A4 (en) | 2009-07-14 | 2010-07-13 | Mixture of slab production |
US13/379,261 US20120167801A1 (en) | 2009-07-14 | 2010-07-13 | Mixture for slab production |
CN2010800680607A CN103118846A (en) | 2009-07-14 | 2010-07-13 | Mixture of slab production |
KR20137003695A KR20130088144A (en) | 2009-07-14 | 2010-07-13 | Mixture of slab production |
AU2010273168A AU2010273168A1 (en) | 2009-07-14 | 2010-07-13 | Mixture of slab production |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2009903276 | 2009-07-14 | ||
AU2009903276A AU2009903276A0 (en) | 2009-07-14 | Cementitious slab production and processing | |
AU2010900914A AU2010900914A0 (en) | 2010-03-04 | Slab production and processing | |
AU2010900914 | 2010-03-04 | ||
AU2010901414A AU2010901414A0 (en) | 2010-04-01 | Slab production and processing | |
AU2010901414 | 2010-04-01 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2011006194A1 true WO2011006194A1 (en) | 2011-01-20 |
Family
ID=43448794
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2010/000890 WO2011006195A1 (en) | 2009-07-14 | 2010-07-13 | Slab production and processing |
PCT/AU2010/000889 WO2011006194A1 (en) | 2009-07-14 | 2010-07-13 | Mixture of slab production |
PCT/AU2010/000895 WO2011006200A1 (en) | 2009-07-14 | 2010-07-14 | Packaging cementitious products |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2010/000890 WO2011006195A1 (en) | 2009-07-14 | 2010-07-13 | Slab production and processing |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2010/000895 WO2011006200A1 (en) | 2009-07-14 | 2010-07-14 | Packaging cementitious products |
Country Status (10)
Country | Link |
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US (2) | US9126351B2 (en) |
EP (3) | EP2593282A4 (en) |
KR (1) | KR20130088144A (en) |
CN (1) | CN103118846A (en) |
AU (1) | AU2010273168A1 (en) |
CL (1) | CL2013000145A1 (en) |
CO (1) | CO6680638A2 (en) |
EA (1) | EA201390097A1 (en) |
WO (3) | WO2011006195A1 (en) |
ZA (1) | ZA201301100B (en) |
Cited By (1)
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WO2013013271A1 (en) * | 2011-07-27 | 2013-01-31 | William Alexander James Sadler | Laminated product produced by placing one layer onto a semi set partially cured base layer. |
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KR20130088846A (en) * | 2010-07-14 | 2013-08-08 | 새들러 아이피 피티와이 엘티디 | Packaging cementitious products |
US20130262344A1 (en) * | 2012-03-29 | 2013-10-03 | Nick Ritota | Countertop selection, marketing and preview system |
US20140134392A1 (en) * | 2012-11-12 | 2014-05-15 | ForzaStone LLC | Composite stone panels |
IT201600076298A1 (en) * | 2016-07-20 | 2018-01-20 | Luca Toncelli | Method, plant and molds for forming agglomerate slabs |
CN111621859A (en) * | 2019-02-27 | 2020-09-04 | 中蓝晨光化工有限公司 | Preparation method of polybenzazole short fiber |
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- 2010-07-13 EP EP20100799278 patent/EP2593282A4/en not_active Withdrawn
- 2010-07-13 WO PCT/AU2010/000890 patent/WO2011006195A1/en active Application Filing
- 2010-07-13 EA EA201390097A patent/EA201390097A1/en unknown
- 2010-07-13 CN CN2010800680607A patent/CN103118846A/en active Pending
- 2010-07-13 WO PCT/AU2010/000889 patent/WO2011006194A1/en active Application Filing
- 2010-07-13 US US13/379,261 patent/US20120167801A1/en not_active Abandoned
- 2010-07-13 AU AU2010273168A patent/AU2010273168A1/en not_active Abandoned
- 2010-07-13 KR KR20137003695A patent/KR20130088144A/en not_active Application Discontinuation
- 2010-07-13 EP EP10799277.8A patent/EP2593281A4/en not_active Withdrawn
- 2010-07-14 WO PCT/AU2010/000895 patent/WO2011006200A1/en active Application Filing
- 2010-07-14 EP EP10799283.6A patent/EP2593280A4/en not_active Withdrawn
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2013
- 2013-01-14 CL CL2013000145A patent/CL2013000145A1/en unknown
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- 2013-02-13 CO CO13029451A patent/CO6680638A2/en unknown
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2013013271A1 (en) * | 2011-07-27 | 2013-01-31 | William Alexander James Sadler | Laminated product produced by placing one layer onto a semi set partially cured base layer. |
CN103826842A (en) * | 2011-07-27 | 2014-05-28 | 阿贝和布莱德Ip私人有限公司 | Laminated product produced by placing one layer onto semi set partially cured base layer. |
EP2747995A4 (en) * | 2011-07-27 | 2016-03-16 | Abbey And Pride Ip Pty Ltd | Laminated product produced by placing one layer onto a semi set partially cured base layer. |
Also Published As
Publication number | Publication date |
---|---|
US9126351B2 (en) | 2015-09-08 |
CO6680638A2 (en) | 2013-05-31 |
EP2593282A4 (en) | 2014-02-26 |
EA201390097A1 (en) | 2013-06-28 |
US20120167801A1 (en) | 2012-07-05 |
EP2593280A4 (en) | 2015-05-06 |
US20120168991A1 (en) | 2012-07-05 |
EP2593280A1 (en) | 2013-05-22 |
ZA201301100B (en) | 2014-07-30 |
AU2010273168A1 (en) | 2012-01-19 |
AU2010273169A1 (en) | 2011-11-10 |
CN103118846A (en) | 2013-05-22 |
EP2593281A4 (en) | 2014-03-12 |
EP2593282A1 (en) | 2013-05-22 |
KR20130088144A (en) | 2013-08-07 |
CL2013000145A1 (en) | 2013-10-25 |
WO2011006200A1 (en) | 2011-01-20 |
EP2593281A1 (en) | 2013-05-22 |
WO2011006195A1 (en) | 2011-01-20 |
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