Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/005—Devices or processes for obtaining articles having a marble appearance
• • 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
  • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
  • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
  • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
  • B28B13/0225—Feeding specific quantities of material at specific locations in the mould
• • 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
  • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
  • B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
  • B28B3/123—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
  • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
  • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
  • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44F—SPECIAL DESIGNS OR PICTURES
  • B44F9/00—Designs imitating natural patterns
  • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
  • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
  • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
  • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
  • B29C67/244—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length by vibrating the composition before or during moulding

Definitions

• the invention relates to a composite stone having an irregular and long-veined appearance similar to that of the Calacatta marble surface and cross-section, and its production method.
• Engineered Stone Slabs are a type of composite stone, usually containing quartz, binder (resin) and additives (catalyst, accelerator, etc.) in various sizes.
• Engineered Stone Slabs are used as substitutes for natural stone slabs. However, in terms of physical and chemical properties, they are far superior to natural stones.
• the production steps of quartz stone are the mixing of quartz and binders of various sizes, transferring the prepared mixture into the mould, removing the air in the mixture by vibratory compaction process under vacuum, heat curing process, and polishing process.
• Granular quartz particles of 65% by weight and small size quartz powder of 25% by weight are used in "Quartz Stones".
• resin about 9% by weight and additives about 1% by weight are added.
• the key point of the Quartz Stone production method is the vibratory compaction step performed under vacuum. During the vibratory compaction, the density of quartz particles is increased while the absorption of the air that is wanted to be removed because it is vacuumed is provided. In quartz stones with high packing density, an improvement is observed especially in mechanical and aesthetic properties because the rate of gaps will be minimal.
• the base parts of the composite stone were filled by placing templates in the mould, and then the venous parts. After the vein was added, the templates were removed, and vibratory compaction was performed. Finally, the curing process was performed, and the stone reached its final form. However, shifts in the patterns occurred during the vibratory compaction process after the templates used in this technique were removed from the mould.
• the appearance and dimensions of the vein were determined in the mould using a template and then filled with the mixture formed by using quartz, resin, and additives. Correction apparatuses were used to remove the appearance of the templates after the vein application.
• channels were formed on the artificial stone surface by means of two cylindrical bar apparatus placed under the composite stone slab and these channels were filled with material by means of sprayers containing more than one hole. A three-dimensional vein structure was formed on the final product.
• the purpose of the invention is to develop a composite stone product with a vascular texture similar to that of the Calacatta marble surface.
• Another purpose of the invention is to develop base formulations to provide vascular texture similar to that of Calacatta marble surface.
• Another purpose of the invention is to develop vein formulations to provide vascular tissue similar to that of Calacatta marble surface.
• Another purpose of the invention is to improve the rheological (viscosity) properties of the base and vein formulations.
• Another purpose of the invention is to open the physical channels in the composite stone product according to the rheological properties of the base formula and to fill the channels with the vein formula.
• Another purpose of the invention is to provide the channel shape and channel thickness necessary to form the vascular tissue similar to that of the Calacatta marble surface.
• the invention is a method of producing a composite with a thick, long, and irregular venous structure as on the surface of Calacatta marble and includes the following steps:
• At least one mineral 45 pm in size selected from the group consisting of quartz, silica sand, quartzite, quartz sand, amorphous quartz, b- Quartz, a-cristobalite, b-cristobalite, a-tridimite, b-tridimite, milky quartz, transparent quartz and various combinations of 20-40% by weight,
• At least one mineral 100- 400 pm in size selected from the group consisting of quartz, silica sand, quartzite, quartz sand, amorphous quartz, b-Quartz, a-cristobalite, b-cristobalite, a-tridimite, b-tridimite, milky quartz, transparent quartz and various combinations of 60-80% by weight,
• At least one mineral 45 pm in size selected from the group consisting of quartz, silica sand, quartzite, quartz sand, amorphous quartz, b- Quartz, a-cristobalite, b-cristobalite, a-tridimite, b-tridimite, milky quartz, transparent quartz and various combinations of 20-40% by weight,
• At least one mineral 100- 400 pm in size selected from the group consisting of quartz, silica sand, quartzite, quartz sand, amorphous quartz, b-Quartz, a-cristobalite, b-cristobalite, a-tridimite, b-tridimite, milky quartz, transparent quartz and various combinations of %60-80 by weight, and
• the invention is a method of producing composite with a thick, long, and irregular appearance with a venous structure as on the surface of Calacatta marble; Accordingly, within the scope of the invention, a base formulation was developed consisting of quartz and / or silica sand and / or quartzite and / or quartz sand and / or amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a-tridimite and / or b-tridimite and / or milky quartz and / or transparent quartz 45 pm in size and at the rate of %20-40 % by weight and 100- 400 pm in size and at the rate of %60-80 plus resin at the rate of 6-26% by weight.
• vein formulations consisting of quartz and / or silica sand and / or quartzite and / or quartz sand and / or amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a-tridimite and / or b-tridimite and / or milky quartz and / or transparent quartz 45 pm in size at the rate of %20-40 % by weight and 100- 400 pm in size at the rate of %60-80 plus resin at the rate of 6-26% by weight. There was a difference between the base and the vein in resin changing between 0.1% and 10% by weight.
• the viscosity of the resin used in the vein was set to 400-600 cp depending on the vein formula, and the fluidity of the vein was optimized for the formation of long veins on the surface. In addition, a common matrix was formed between the vein and the base by wetting.
• the shape of the vein was arranged depending on the vein design ( Figure- 1). Two different vein design were realized within the scope of the invention.
• the fine- textured vein map will be obtained with a roy-cut robot using powder pigments of different colors.
• the thick- textured vein map will be obtained with a roy-mix robot using different formulations.
• products can have a natural marble appearance unlike standard quartz surfaces.
• vein (wet mixture) formulations containing resin at the rate of 6-16% by weight with a viscosity of 400-600 Cp were formed according to the fluidity properties of the base formula containing quartz and / or silica sand and / or quartzite and / or quartz sand and / or amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a-tridimite and / or b-tridimite and / or milky quartz and / or transparent quartz 45 pm in size at the 20 - 40% and 100 - 400 pm in size at the rate of % 60-80 plus resin at the rate of % 6-26 by weight, respectively.
• the resin content in the base was increased in the range of 0.1-10% in order to make the base better wetted.
• the resin content in the base was used as 6-26%. Since using only quartz, a-quartz and / or silica sand and / or quartzite and / or quartz sand as raw materials in the base formula provided an opaque and unnatural appearance; amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a-tridimite and / or b-tridimite and / or milky quartz and / or transparent quartz were used and a natural appearance was obtained on the surface of the composite stone.
• Iron oxide, titanium dioxide, copper chromium oxide, carbon black, manganese iron oxide (in spinel and hematite structure), chromium iron oxide (in hematite structure) pigments were used in vein and base formulations in order to obtain the vein colors of Calacatta marble on the composite stone surface.
• the unsaturated polyester resin used as a standard in production has a viscosity in the range of 500-700 Cp.
• a lower viscosity resin was required to apply the resin with the robot. Therefore, the viscosity of the resin was reduced to 50-150 Cp by adding styrene monomer at the rate of 5 to 40% by weight into unsaturated polyester resin.
• an additional robotic arm was added next to the current robotic arm in order to achieve the thick vein appearance of the original Calacatta marble.
• the vein discarded from Roy Mix is called "wet mixture”.
• the viscosity of the wet mixture discarded from Roy Mix's chamber can be formed with similar viscosity of the base.
• formulas of wet mixture close to the viscosity of the base were formed.
• the base resin rate was increased in the range of 1-10% for better wetting of the base.
• the edges of the vein were wetted with coloured resin (paste pigment).
• Shapes of the channels, the thickness of the channels, the design of the apparatus and jugs that can open channels were investigated to form the veins.
• Experiments were conducted at the pilot facility with the jags of these channel opener apparatus and studies were carried out to determine the fluidity of the vein formula to fill the channels according to the shape and colour of the designed veins.
• the effect of formula compliance of the base and vein on the quartz surface was examined.
• the formation and curing of the with two different formulas were examined under the press and the matrix surface produced by both s was examined during the curing process.
• reaction times were measured by applying exothermic reaction on vein and base. Problems that may occur in curing together were investigated when they exhibited different reaction times. Studies on the waiting time of the base formula started during the vein formation.
• Base formulation samples (Base-1, Base-2, Base-3, Base-4, Base-5, Base-6, Base-7, and Base-8) which were formed in the laboratory and consisted of quartz and / or silica sand and / or quartzite and / or quartz sand and / or amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a- tridymite and / or b-tridymite and / or milky quartz and / or transparent quartz 45 pm in size at the rate of 20 - 40% by weight and 100 - 400 pm in size at the rate of 60-80 % by weight, respectively, plus resin at the rate of 6-26% by weight were tested mechanically. Bending Resistance, Impact Resistance, Abrasion Resistance and Water Absorption Rates were measured (Table 1). Table 1. Prototype mechanical test results
• vein formulations consisting of quartz and / or silica sand and / or quartzite and / or quartz sand and / or amorphous quartz and / or b-quartz and / or a-cristobalite and / or b-cristobalite and / or a-tridymite and / or b-tridymite and / or milky quartz and / or transparent quartz 45 pm in size at the rate of %20-40 % by weight and 100- 400 pm in size at the rate of %60-80, respectively, plus resin at the rate of 6-26% by weight.
• Formulation studies have been performed with different proportions of resin, micronized quartz, and granular quartz. Formation studies were performed with quartz, silica sand, quartzite, quartz sand, amorphous quartz, b-Quartz, a- cristobalite, b-cristobalite, a-tridymite, b-tridymite, milky quartz, transparent quartz raw materials in order to obtain the appearance of Calacatta marble. Iron oxide, titanium dioxide, copper chromium oxide, carbon black, manganese iron oxide (spinel and hematite structure), chromium iron oxide (hematite structure) pigments were used in the formulation in order to obtain the vein colours of Calacatta marble in quartz formulations with different properties.
• the viscosity of the standard resin used in production is in the range of 500-700 cp. A lower viscosity resin was required to apply the resin with the robot. For this reason, the viscosity of the resin was reduced to 50-150 Cp by adding styrene monomer at the rate of 5-40% by weight into the unsaturated polyester resin.
• vein maps with Carrara marble appearance were drawn using Rhinoceros program.

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• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Chemical & Material Sciences (AREA)
• Structural Engineering (AREA)
• Compositions Of Macromolecular Compounds (AREA)
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Citations (3)

• 2019
  • 2019-10-15 TR TR2019/15846A patent/TR201915846A1/tr unknown
  • 2019-11-18 WO PCT/TR2019/050967 patent/WO2021076070A1/en active Application Filing

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