WO2021136126A1 - 一种把颗粒骨料压制成板材的制备工艺及成型设备 - Google Patents

一种把颗粒骨料压制成板材的制备工艺及成型设备 Download PDF

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Publication number
WO2021136126A1
WO2021136126A1 PCT/CN2020/139842 CN2020139842W WO2021136126A1 WO 2021136126 A1 WO2021136126 A1 WO 2021136126A1 CN 2020139842 W CN2020139842 W CN 2020139842W WO 2021136126 A1 WO2021136126 A1 WO 2021136126A1
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Prior art keywords
mixture
plate
slap
pressure
pressing
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PCT/CN2020/139842
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English (en)
French (fr)
Inventor
杨绍良
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杨绍良
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Publication date
Application filed by 杨绍良 filed Critical 杨绍良
Priority to US17/789,004 priority Critical patent/US20230041629A1/en
Publication of WO2021136126A1 publication Critical patent/WO2021136126A1/zh

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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
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/04—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form with one ram per mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/022—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space whereby the material is subjected to vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/082—Producing shaped prefabricated articles from the material by vibrating or jolting combined with a vacuum, e.g. for moisture extraction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/006—Pressing by atmospheric pressure, as a result of vacuum generation or by gas or liquid pressure acting directly upon the material, e.g. jets of compressed air
    • 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
    • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/022—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form combined with vibrating or jolting
    • 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
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
    • 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
    • B28B7/0097—Press moulds; Press-mould and press-ram assemblies
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/04—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space co-operating with a fixed mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/06—Platens or press rams
    • B30B15/062—Press plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/30—Feeding material to presses
    • B30B15/302—Feeding material in particulate or plastic state to moulding presses

Definitions

  • the invention relates to a preparation process for pressing granular aggregates into plates, and at the same time relates to a forming device for pressing granular aggregates into plates.
  • the first processing method such as the utility model patent with the Chinese patent number CN201120319813.9, discloses an artificial quartz stone press, which includes a base, racks installed on both sides of the base, and a reducer installed at the bottom of the base.
  • the shock spring, the enclosure frame and the punch installed on the machine base, the machine base is provided with a guide post, the enclosure frame and the punch are provided with a shaft sleeve, and the enclosure frame and the punch are movably connected to the guide post through the shaft sleeve
  • the upper end of the guide post is fixedly connected to the organic roof, and the punch hydraulic cylinder and the enclosure frame hydraulic cylinder are arranged on the top of the machine.
  • the punch hydraulic cylinder is connected to the punch through the hydraulic cylinder connection seat, and the enclosure frame hydraulic cylinder is connected to the hydraulic cylinder connection seat.
  • the punch is provided with a vibration motor; a transmission belt is provided above the frame and the base, and both ends of the transmission belt are provided with transmission wheels.
  • pressure is applied by hydraulic pressure and then vibrated by a vibration motor.
  • this pressing method has the following disadvantages. Because the vibration motor is a high-frequency vibration work, the hydraulic system is always in the process of pressurizing and releasing cycles. , The hydraulic pressure has been in a state of virtual pressure, unable to exert enough pressure on the plate.
  • this processing method is similar to the kneading processing method, the material is kneaded like kneading, it is difficult to improve the strength of the board. In order to satisfy the sheet forming, a lot of time is wasted.
  • the second processing method such as the Chinese Patent Application No. 201510026692.1, discloses a method for preparing a heavy hammer-beating synthetic stone and a molding machine, including a base, a heavy hammer installed on the base, and A driver for driving the heavy hammer, the base has a material loading area, and the heavy hammer slaps the material loading area.
  • a heavy hammer is used to slap the material. Since a large enough slap force is applied to the material, the gap between the granular aggregates is reduced as much as possible, thereby increasing the strength of the plate.
  • the second processing method can effectively solve the defects caused by the first processing method.
  • the above technical solution uses a heavy hammer to slap up and down to make high-strength plates by slapping particles and powder materials up and down.
  • this technical solution is an up and down slap type realization method, this method matches the material ratio of the plate materials.
  • the level configuration requirements are very high. If the grade configuration of the plate material is deviated, when the plate material is hit by a heavy hammer, the movement amount of the plate material of different sizes will be inconsistent, causing the plate to crack, bulge, hollow, and material movement deviation.
  • the high level configuration requirements of the ratio brought by this technical solution will lead to the need for high-precision production standards for batching accuracy; the heavy hammer caused by this technical solution causes inconsistent movement of different sizes of plate materials There will be uneven distribution of the plate materials of different sizes in the pressed plate; the heavy hammer caused by this technical solution will cause the inconsistent movement of the plate materials of different sizes, and the pressed plate will be deformed during baking. phenomenon.
  • the heavy hammer slap of this technical scheme is that multiple vibrators are driven and connected together to form a synchronous driving group. At least one synchronous driving group is provided on the heavy hammer. The structure is installed on the heavy hammer plate to realize the upper and lower heavy hammers. slap.
  • the synchronous drive group belongs to a mechanical structure, and the mechanical structure will have some errors in processing accuracy, installation accuracy, and mechanical operation. Due to the mechanical error, the synchronous drive group cannot achieve 100% complete synchronization. Therefore, the error will often occur when the material is pushed to one side when the plate is pressed and slapped, causing the plate to appear thick on one side and thin on the other.
  • heavy hammer beating, pressurizing, and vacuuming are the current new methods and equipment for pressing particles and powder materials into plates. When heavy hammer beating, it is easy to cause the resonance of the plate material and cannot realize the thin plate pressing.
  • the above technical solution can be called a "slap" method, which realizes the improvement of the productivity of the plate industry but seriously affects the pass rate of the plate.
  • the instability of the pass rate always lacks a mature, large-scale application, and fast forming speed. And craftsmanship.
  • the technical problem to be solved by the present invention is to overcome the above-mentioned shortcomings of the prior art and provide a preparation process and molding equipment for pressing granular aggregates into plates with high strength and suitable for large-scale promotion.
  • a preparation process for compressing granular aggregates into plates includes the following steps: A, ingredients, mixing granular aggregates of different particle sizes and liquid materials in proportions to form a mixture; B, cloth, mixing The mixture is evenly arranged on the conveyor belt or in the mold frame according to the required thickness; C, vacuum treatment, vacuum exhaust treatment of the mixture; D, molding, in the molding process, a pressure plate is covered on the mixture, The pressure plate always exerts a downward pressure on the mixture.
  • the slap hammer located above the pressure plate continuously slaps the pressure plate.
  • the pressure plate produces The pressure forms a continuous holding force on the mixture, the slap force generated by the up and down movement of the slap hammer is transmitted to the mixture through the pressure plate, and the pressure generated by the pressure plate and the slap generated by the slap hammer
  • the composite force formed by the superposition of forces acts together in the mixture, so that the granular aggregates in the mixture move and fill each other under the action of the composite force, and the liquid material is filled into the gaps of the granular aggregates , Forming a dense sheet structure; E, curing, curing the formed sheet structure to obtain a finished product.
  • the preparation process for compressing granular aggregates into plates according to the present invention also has the following subsidiary technical features:
  • the slap force generated by the slap hammer is evenly distributed on the mixture through the pressure plate.
  • the pressure generated by the pressure plate includes the pressure generated by the pressure plate's self-gravity and vacuum.
  • the pressure generated by the pressure plate includes the pressure generated by the gravity of the pressure plate, the pressure generated by the vacuum, and the externally applied pressure.
  • flapping hammer is in a free and no resistance state during the forming process.
  • a forming device for pressing granular aggregate into a plate comprising a base, a weight mounted on the base, and a driver for driving the weight, and the base has a load
  • the material area further includes a pressure plate, the pressure plate covers the material carrying area, and the weight is located above the pressure plate. When working, the pressure plate always exerts a downward pressure on the material carrying area.
  • the heavy hammer continuously slaps the pressure plate, the pressure generated by the pressure plate forms a continuous holding force on the mixture, and the slap force generated by the up and down movement of the slap hammer is transmitted through the pressure plate
  • the composite force formed by the superposition of the pressure generated by the pressing plate and the slap force generated by the slap hammer acts together in the mixed material in the loading zone.
  • a sealing structure is provided between the mold frame and the base, a sealing mechanism is provided between the mold frame and the pressure plate, and the mold frame, the base and the pressure plate form a containment structure.
  • the vacuum chamber of the mixture, the vacuum chamber is connected with the vacuum system.
  • the limiting device abuts against the side wall of the heavy hammer.
  • a contact protrusion is provided on the limiting device, and the contact protrusion is made of a wear-resistant and shock-absorbing material.
  • a suspension member is arranged on the pressure plate, and the suspension member is hooked on the heavy hammer. During operation, the suspension member is separated from the pressure plate or the heavy hammer.
  • the preparation process for compressing granular aggregates into plates has the following advantages: the present invention adopts a brand-new preparation process, which is a combination of "pressure + slap", During the molding process, the pressure plate is always not separated from the mixture, and the pressure plate always exists on the mixture. The slap force is only applied to the pressure plate, and the slap force is transmitted to the mixture through the pressure plate. Since the slap force does not directly act on the mixture, it can reduce the damage to the mixture when the slap force is uneven, and reduce the generation of cracks. In addition, the process of the present invention can meet the processing requirements of the thin plate, and prevent the slap force of the thin plate from directly acting on the mixture during the forming process.
  • the molding equipment for compressing granular aggregates into plates provided by the present invention has the following advantages: the heavy hammer striking force of the molding equipment of the present invention will only generate up and down force on the mixture, not Will produce horizontal lateral force on the mixture; solve the problem of uneven force on the plate during the forming and pressing process. The striking force of the heavy hammer of the present invention will not be weakened by the influence of the vacuum.
  • Fig. 1 is a front view of the present invention.
  • Fig. 2 is a left side view of the present invention.
  • Fig. 3 is a plan view of the present invention.
  • Fig. 4 is a perspective view of the present invention.
  • Fig. 5 is a front cross-sectional view of the present invention.
  • Fig. 6 is a side sectional view of the present invention.
  • Fig. 7 is a cross-sectional view of the weight, mold frame and pressing plate of the present invention.
  • Fig. 8 is a perspective view of the mold frame of the present invention.
  • Fig. 9 is an enlarged view of A in Fig. 6.
  • the invention provides a preparation process for pressing granular aggregates into plates, including the following steps:
  • Ingredients mix granular aggregates and liquid materials with different particle sizes in proportion to form a mixture; granular aggregates and liquid materials with different particle sizes are selected according to the vacuum stone style and proportioned, such as quartz stone particles Aggregate, or other stone particles, etc.
  • the liquid material can be a liquid filler.
  • the present invention adopts a "pressure + slap force" combination method for forming, which can effectively solve the problems of "pressure vibration" and "single slap force” in the prior art.
  • the pressing plate always presses the mixture to prevent the mixture from rebounding when it is slapped and lifted, thereby making it difficult to form the mixture and effectively reducing cracks in the mixture.
  • the processing effect of the thin plate is better.
  • the slap force directly acts on the mixture, the thickness of the mixture is different, and the slap force will slap the mixture and cause cracks.
  • the invention is provided with a pressing plate, so that the slap force acts on the mixture indirectly, reduces the damage of the slap force to the mixture, reduces cracks, and improves the yield.
  • the slap force generated by the slap hammer is evenly distributed on the mixture through the pressure plate.
  • the pressing plate in the present invention has a whole plate structure, which can evenly disperse the slap force, so that the force of the mixture is uniform, does not cause problems of material accumulation or material running, and improves the plate rate.
  • the pressure generated by the pressing plate includes the pressure generated by the gravity of the pressing plate and the vacuum.
  • the pressing plate in the present invention is made of a whole piece of steel plate, which has a large enough weight, and its own gravity can meet the "pressure" requirement. Since a vacuum is formed between the pressure plate and the mixture, atmospheric pressure also acts on the pressure plate, causing the pressure plate to further increase the "pressure".
  • the pressure generated by the pressure plate in the present invention may also include the pressure generated by the pressure of the pressure plate, the pressure generated by the vacuum, and the externally applied pressure. The externally applied pressure may increase a hydraulic mechanism to apply hydraulic pressure to the pressure plate.
  • a pneumatic mechanism can also be added, or additional counterweights can be added to increase the pressure generated by the pressure plate.
  • the above-mentioned structure of the present invention enables the mixture to always have enough pressure to maintain a specific state during the molding process, so that when the slap hammer is lifted, the mixture does not rebound.
  • the flapping hammer is in a free and no resistance state during the forming process.
  • the slap hammer in the present invention is located outside the vacuum chamber and will not be affected by the vacuum force during the working process.
  • the slap hammer in the present invention is in a suspended state during operation, and can generate a sufficiently large slap force.
  • the present invention provides a molding device for pressing granular aggregate into a plate, including a base 1, a slap hammer 2 installed on the base 1, and a driving station.
  • the base 1 has a material loading area, and further includes a pressure plate 4 covering the material loading area, and the slap hammer 2 is located on the material loading area.
  • the slap force generated by the up and down movement of the slap hammer 2 is transmitted to the mixture in the loading zone through the pressure plate 4, and the pressure generated by the pressure plate 4 is equal to
  • the composite force formed by the superimposition of the slap force generated by the slap hammer 2 acts together in the mixture in the loading zone.
  • the present invention adds a pressure plate structure to the slap hammer equipment.
  • the pressure plate 4 is a plate-like structure, and the size of the pressure plate 4 can be the same to cover the entire mixture.
  • the pressure plate 4 in this embodiment is made of steel plate and has a large enough size. The weight of the resulting pressure meets the requirements.
  • the pressing plate 4 When working, the pressing plate 4 always presses the mixture so that the mixture does not rebound, which is beneficial to rapid molding of the mixture and shortens the molding time. Since the slap force acts on the mixture indirectly, the mixture will not rebound.
  • the slap hammer 2 can adopt a higher slap frequency and a higher slap force to further improve the mixing speed and shorten Molding time improves production efficiency.
  • the above-mentioned embodiment of the present invention further includes a mold frame 5, and a part of the structure of the pressing plate 4 is inserted into the mold frame 5.
  • the mold frame 5 is a frame structure made of metal, which plays a role of limiting the mixed material and preventing material leakage or material running.
  • at least part of the structure of the pressing plate 4 is located in the mold frame 5. Conducive to compacting the mixture in the mold frame 5.
  • the above-mentioned embodiment of the present invention further includes that a sealing structure 51 is provided between the mold frame 5 and the base 1, and the mold frame 5 and the pressure plate 4 are separated from each other.
  • a sealing mechanism 52 is arranged between the mold frame 5, the base 1 and the pressing plate 4 to form a vacuum chamber containing the mixture, and the vacuum chamber is connected with a vacuum system.
  • the vacuum chamber of the present invention is formed by the mold frame 5, the base 1 and the pressure plate 4, and the vacuum force can further increase the pressure generated by the pressure plate 4. If the slap hammer 2 is not located in the vacuum chamber, the vacuum force will not affect the slap hammer 2 and the slap force generated by the slap hammer 2 will not be weakened.
  • the sealing structure 51 is at least two sealing rings installed at the bottom of the mold frame 5, and the sealing rings are compressed on the base 1.
  • the sealing mechanism 52 is a toothed sealing ring installed on the side wall of the mold frame 5, and the toothed sealing ring abuts against the side wall of the pressure plate 4.
  • the above-mentioned embodiment of the present invention further includes a limiting device 6, and the limiting device 6 abuts against the side wall of the slap hammer 2.
  • the limiting device 6 is a set of limiting blocks, which has a limiting effect on the slap hammer 2 and prevents the slap hammer 2 from shifting during the slap process, so that the slap force formed by it is up and down. Sporty slap.
  • the above-mentioned embodiment of the present invention further includes a limiting device 6 arranged on the mold frame 5, and the limiting device 6 abuts against the slap Heavy hammer 2 on the side wall.
  • the limiting device 6 in this embodiment is set on the mold frame 5, and the limiting device plays a limiting role on the slap hammer 2.
  • the above-mentioned embodiment of the present invention further includes that the limiting device 6 is provided with a contact protrusion 61, and the contact protrusion 61 is made of a wear-resistant and shock-absorbing material.
  • the contact protrusion 61 plays a supporting role and reduces the friction of the slap hammer 2.
  • a groove 62 is formed on the limiting device 6, and the contact protrusion 61 is installed in the groove 62.
  • the above-mentioned embodiment of the present invention further includes that a suspension member 41 is provided on the pressure plate 4, and the suspension member 41 is hooked on the slap hammer 2 and works At this time, the suspension member 41 is separated from the pressing plate 4 or the slap hammer 2.
  • the slap hammer 2 is further provided with a hammer hydraulic cylinder 21.
  • the hammer hydraulic cylinders 21 are four sets of hydraulic mechanisms that can lift the slap hammer 2. During the lifting process, The suspension member 41 can lift the pressure plate 4 together, so that the pressure plate 4 is separated from the mixed material, which is convenient for transportation.
  • the mold frame 5 is also provided with a mold frame hydraulic cylinder 53, and the suspension member 41 may also be connected to the mold frame 5, so as to lift the mold frame 5 while driving the pressure plate 4 .
  • a plurality of said drivers 3 are synchronously connected together to form a synchronous driving group, and the top of the slap hammer 2 is provided with at least four synchronous groups.
  • Drive groups each two sets of synchronous drive groups are connected together by a synchronization mechanism.
  • the synchronization mechanism includes a plurality of synchronization wheels 31 and a plurality of synchronization belts 32, the synchronization wheels 31 are installed at the connection between adjacent drives 3, and the synchronization wheels 31 are connected with the rotating shaft of the drive 3.
  • Synchronous wheels 31 in two adjacent synchronous driving groups are connected by the synchronous belt 32, so as to realize synchronous operation of the adjacent two synchronous driving groups.
  • the synchronization mechanism in the present invention is composed of a plurality of synchronization wheels and a synchronization belt, and the synchronization effect is better.
  • there are four groups of synchronous driving groups which are synchronized in pairs, and the rotation direction is opposite, which is one forward and the other reverse.
  • This structure has a better synchronization effect.
  • all four synchronous driving groups can be connected together by a synchronous wheel and a synchronous belt to realize the synchronization of the four groups.
  • when there are six synchronous drive groups three of them are synchronized, and the other three are synchronized. That is, the even number setting is used, and the halves are synchronized separately.
  • the synchronous wheel 31 is a gear wheel
  • the synchronous belt 32 is a toothed belt.
  • the synchronous belt 32 meshes with the synchronous wheel 31 to realize synchronous operation.
  • the above-mentioned embodiment of the present invention further includes that a hollow part is formed in the middle of the mold frame 5, a wing plate 54 is formed on the side of the mold frame 5, and the base 1 is provided with a mold frame hydraulic cylinder 53, and the mold frame hydraulic cylinder 53 abuts on the wing plate 54.
  • the mold frame 5 functions as a frame material, so that the vacuum stone mixture is located in the hollow part and will not leak around.
  • the mold frame hydraulic cylinder 53 is used to drive the mold frame 5 up and down, and the wing plate 54 is more conducive to the installation of the mold frame hydraulic cylinder 53.
  • the above-mentioned embodiment of the present invention further includes that a guide post 15 is provided on the base 1, a guide cylinder 55 is provided on the wing plate 54, and the guide post 15 penetrates Into the guide cylinder 55.
  • the guide post 15 and the guide cylinder 55 make the lifting and lowering of the mold frame 5 more stable.
  • the above-mentioned embodiment of the present invention further includes that a step 16 is formed on the base 1, and the mold frame hydraulic cylinder 53 and the guide post 15 are arranged on the step 16 on.
  • the step 16 is provided to facilitate the installation and fixation of the mold frame hydraulic cylinder 53 and the guide post 15.
  • the above-mentioned embodiment of the present invention further includes that the upper side of the flapping hammer 2 extends outward to form a protrusion 28, and the hammer hydraulic cylinder 21 abuts against the ⁇ projection 28.
  • the protruding portion 28 facilitates the pressing of the hammer hydraulic cylinder 21.
  • the above-mentioned embodiment of the present invention further includes that the base 1 is formed by stacking multiple layers of plates, and the weight of the base 1 is greater than that of the slap hammer 2. pull.
  • the base 1 of the present invention has a heavy weight, and the flapping hammer 2 will not be displaced during the flapping process.
  • the corresponding contents of the two embodiments can be mutually cited. That is, the content in the device embodiment is used in the process, and the content in the process embodiment can also be used in the device.
  • the granular aggregate is filled with each other under the combined force of the vacuum force, the pressure and the hammering force, and the liquid filler is filled into the gaps of the granular aggregates to form a vacuum
  • the closed body is the vacuum stone.
  • granular aggregates of different particle sizes can be filled with each other, large-sized granular aggregates are close to each other, and small-sized granular aggregates can fill the gaps between large-sized granular aggregates.
  • the gap between the gaps is filled by the filling unit body.
  • the flexible liquid filling film on its surface is deformed according to the size and shape of the gap, so as to fill all gaps as densely as possible, and discharge the gaps. air.
  • the invention utilizes the principle of the Magdeburg hemisphere to prepare a vacuum stone, which is closer to natural stone in nature, and the overall performance of the vacuum stone is also close to natural stone.
  • the forming principle of the vacuum stone of the present invention uses a binder to bond granular aggregates of various particle diameters together, not only the strength of the synthetic stone is not high, but also it is not environmentally friendly.
  • the vacuum stone of the present invention uses atmospheric pressure to press aggregates of various particle sizes together, which has higher strength and is more environmentally friendly.
  • the filling concept proposed by the present invention means that the particle aggregates of various particle sizes move and fit each other, and the particle aggregates of the next-level particle size are filled in the gaps of the particle aggregates of the larger one-level particle size, and all the gaps are completed by the filling unit body. Of filling.
  • the filling process of the present invention is different from the pressing process in the prior art.
  • the particle aggregates of various particle sizes are not mixed with the liquid filler, and the particle aggregates of various particle sizes can better fit each other, and the usage amount of the liquid filler is also reduced.
  • the liquid filler is only mixed with the fine particle size solid particle filler to form a filling unit with the smallest particle size, and the prepared filling unit is then used for the mixing of granular aggregates, so that the filling unit is wrapped
  • the granular aggregates of various particle diameters and the granular aggregates that wrap the filling unit body can be better filled with each other during the molding process, and the gap between them is filled by the filling unit body, and finally a vacuum sealed body is formed.
  • the surface of the particle aggregates of various particle sizes is wrapped with a binder, it is difficult for the fine particle aggregates to fill the gaps of the particle aggregates during the pressing process. Too much binder is used. During the pressing process, the excess binder is difficult to discharge from the synthetic stone. The final result is a synthetic stone structure formed by the bonding of the binder. The bonding strength of the binder determines the synthesis. The strength of the stone.
  • the present invention does not need to sinter the vacuum stone, is a sinter-free preparation process, and is more environmentally friendly. Therefore, the preparation process proposed by the present invention is a completely new process.
  • the filling unit in the present invention is to mix fine particle size solid particle filler and liquid filler to form a flexible liquid filling film on the surface of the solid particle filler; the fine particle size solid particle filler in the present invention is the smallest
  • the particle size filling unit, the flexible liquid filling film has the characteristics of plastic shape, and can change the shape according to the size of the gap during the filling process, so as to adapt to the gaps of different sizes and to fill the gaps densely.
  • the solidification is to change the liquid filler from a liquid state to a solid state.
  • the liquid filler described in the present invention refers to a liquid with the characteristic of transforming from a liquid state to a solid state. This liquid also needs to be kept in a solid state for a long time under normal conditions to eliminate the air in the gap and make it difficult for air to enter the gap.
  • the liquid filler may have the characteristic of changing from liquid to solid, and includes organic resins and inorganic resins.
  • the organic resin includes acrylic resin, unsaturated resin, acrylic resin or epoxy resin
  • the inorganic resin includes soybean-based resin or rubber-based resin.
  • liquid fillers have the characteristic of transforming from liquid to solid and can meet the needs of vacuum stone.
  • the liquid filler described in the present invention refers to a liquid that has the characteristic of transforming from a liquid to a solid. This liquid also needs to be kept in a solid state for a long time under normal conditions, so as to eliminate the air in the gap and make it difficult for air to enter the gap, such as the above Various resins, etc., these resins transform from liquid to solid by themselves or under the action of a catalyst.

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Abstract

一种把颗粒骨料压制成板材的制备工艺及成型设备，包括如下步骤：A、配料，将不同粒径的颗粒骨料和液态物料按照比例混合，形成混合料；B、布料，将混合料按照所需厚度平整的布置在输料带上或模框（5）内；C、真空处理，对混合料进行真空排气处理；D、成型，在成型过程中，在混合料上覆盖一压板（4），压板（4）始终施加一个向下的压力于混合料上，位于压板（4）上方的拍击重锤（2）连续拍击压板（4），在拍击重锤（2）拍击的过程中，压板（4）产生的压力对混合料形成持续的保持力，拍击重锤（2）上下运动产生的拍击力经压板（4）传导至混合料中，压板（4）产生的压力和拍击重锤（2）产生的拍击力叠加形成的复合力共同作用于混合料中，使混合料中的颗粒骨料在复合力的作用下互相运动填充，并将液态物料填充到各颗粒骨料的缝隙中，形成致密板材结构；E、固化，对成型的板材结构进行固化，得到成品。

Description

一种把颗粒骨料压制成板材的制备工艺及成型设备 技术领域
本发明涉及一种把颗粒骨料压制成板材的制备工艺，同时涉及用于把颗粒骨料压制成板材的成型设备。
背景技术
天然石材作为建筑材料的重要部分，因为其色彩多样化，开发容易，自古以来一直被人广泛使用。但是随着其开采量的过度增加，开采利用率低等原因，天然石材的开采逐步受到限制，特别是欧洲国家，已经禁止了天然石材的开采。而且每个矿产区的产品，其花色，品种都是独一的，更增加了其使用上的难度。人们一直在寻找其替代品。随着经济的发展，建筑装饰材料日新月异，合成石作为一种新型的装饰材料得到很大的发展机遇。但由于其生产设备的加压系统和振动系统配合使用是一技术难题，致使设备制造复杂、生产运行不稳定、维护返修率高，生产效率无法达到规模化。现有技术中的成型设备主要有两种形式，其中第一种是“压+振”的磨压方式，第二种是重锤拍击方式。
第一种加工方式，如中国专利号为CN201120319813.9的实用新型专利，公开了一种人造石英石压机，包括机座、安装在机座两侧的机架、安装在机座底部的减震弹簧、安装于机座上的围框及冲头，所述的机座上设置有导柱，围框及冲头上设置有轴套，围框及冲头通过轴套活动连接于导柱上，导柱的上端固接有机顶，机顶上设置有冲头液压缸及围框液压缸，冲头液压缸通过液压缸连接座连接于冲头上，围框液压缸通过液压缸连接座连接于围框上，围框的底部及与冲头连接部位设置有真空密封条，冲头上设置有振动电机；机架及机座上方设置有传动带，传动带的两端设置有传动轮。在上述技术方案中，通过液压施加压力，再由振动电机进行振动，但这种 压板方式存在如下缺点，由于振动电机是高频振动的工作，致使液压系统始终处于加压和释放的循环过程中，液压一直处于虚压状态，无法对板材施加足够的压力。同时,这种加工方式类似于搓揉加工方式，物料像揉面一样被搓揉，难以提高板材的强度。为了满足板材成形，需要浪费大量的时间。
第二种加工方式，如中国专利申请号为201510026692.1号发明专利申请，公开了一种重锤拍击式合成石制备工艺和成型机，包括基座、安装在所述基座上的重锤和驱动所述重锤的驱动器，所述基座上具有载料区，所述重锤拍击所述载料区。在该加工方式中，采用重锤对物料进行拍击，由于对物料施加了足够大的拍击力，使得颗粒骨料之间的间隙尽量缩小，从而提高了板材的强度。第二种加工方式能够有效的解决第一种加工方式所带来的缺陷。上述技术方案利用重锤来进行上下拍击是对颗粒及粉体物料进行上下拍击可以做出高强度板材，但此技术方案因为是上下拍击式的实现方式，此方式对板材物料配比的等级配置要求很高。如板材物料的等级配置出现偏差，板材物料在受到重锤拍击时会导致不同大小的板材物料的运动量不一致使板材出现开裂、起鼓、空洞、物料运动跑偏等现象。此种技术方案所带来的配比的等级配置要求很高会导致配料精度需要有高精度的生产标准；此种技术方案所带来的重锤拍击时导致不同大小的板材物料的运动量不一致会出现所压制板材不同大小的板材物料在板材分布不均匀现象；此种技术方案所带来的重锤拍击时导致不同大小的板材物料的运动量不一致会出现所压制板材在烘烤时出现变形现象。此种技术方案的重锤拍击是多台振动器驱动同步连接在一起，构成一组同步驱动组，重锤上设置有至少一组同步驱动组安装重锤板上的结构来实现上下重锤拍击。此技术方案对同步驱动组的要求很高，但同步驱动组属于机械结构，机械结构会存在一些加工精度、安装精度、机械运转的误差。因机械误差使终存在， 同步驱动组无法实现100％的完全同步，因此误差的存在会时常出现在压制拍击板材时把物料往一边赶的现象，致使板材出现一边厚一边薄的现象。此外，重锤拍击、加压、抽真空是目前把颗粒及粉体料压制成板材的新型方法和设备重锤拍击时容易种造成板材物料的共振无法实现薄板压制。以上技术方案可以称为“拍击”的方式，实现板材行业生产率的提高但严重影响了板材的合格率，合格率的不稳定始终缺少一种成熟、大规模应用、成型速度快的板材成型设备和工艺。
发明内容
本发明所要解决的技术问题在于克服上述现有技术之不足，提供一种具有强度高、适合大规模推广的把颗粒骨料压制成板材的制备工艺和成型设备。
按照本发明提供的一种把颗粒骨料压制成板材的制备工艺，包括以下步骤，A、配料，将不同粒径的颗粒骨料和液态物料按照比例混合，形成混合料；B、布料，将混合料按照所需厚度平整的布置在输料带上或模框内；C、真空处理，对混合料进行真空排气处理；D、成型，在成型过程中，在混合料上覆盖一压板，所述压板始终施加一个向下的压力于混合料上，位于所述压板上方的拍击重锤连续拍击所述压板，在所述拍击重锤拍击的过程中，所述压板产生的压力对混合料形成持续的保持力，所述拍击重锤上下运动产生的拍击力经所述压板传导至混合料中，所述压板产生的压力和所述拍击重锤产生的拍击力叠加形成的复合力共同作用于混合料中，使混合料中的颗粒骨料在所述复合力的作用下互相运动填充，并将所述液态物料填充到各所述颗粒骨料的缝隙中，形成致密板材结构；E、固化，对成型的板材结构进行固化，得到成品。
按照本发明提供的一种把颗粒骨料压制成板材的制备工艺还具有如下 附属技术特征：
进一步包括，所述拍击重锤产生的拍击力经所述压板均匀分布于混合料上。
进一步包括，所述压板产生的压力包括压板自重力和真空产生的压力。
进一步包括，所述压板产生的压力包括压板自重力、真空产生的压力和外部施加的压力。
进一步包括，所述拍击重锤在成型过程中处于自由无阻力状态。
按照本发明提供的一种用于把颗粒骨料压制成板材的成型设备，包括基座、安装在所述基座上的重锤和驱动所述重锤的驱动器，所述基座上具有载料区，还包括一压板，所述压板覆盖在所述载料区上，所述重锤位于所述压板的上方，在工作时，所述压板始终施加一个向下的压力于所述载料区的混合料上，所述重锤连续拍击所述压板，所述压板产生的压力对混合料形成持续的保持力，所述拍击重锤上下运动产生的拍击力经所述压板传导至所述载料区的混合料中，所述压板产生的压力和所述拍击重锤产生的拍击力叠加形成的复合力共同作用于所述载料区的混合料中。
进一步包括，还包括一模框，所述压板的部分结构插入所述模框中。
进一步包括，所述模框与所述基座之间设置有密封结构，所述模框与所述压板之间设置有密封机构，所述模框、所述基座和所述压板形成一容纳混合料的真空腔，所述真空腔与真空系统相连接。
进一步包括，还包括一限位装置，所述限位装置顶靠在所述重锤的侧壁上。
进一步包括，还包括一设置在所述模框上的限位装置，所述限位装置顶靠在所述重锤的侧壁上。
进一步包括，所述限位装置上设置有接触凸条，所述接触凸条由耐磨减震材料制成。
进一步包括，所述压板上设置有悬挂件，所述悬挂件勾挂在所述重锤上，在工作时，所述悬挂件与所述压板或所述重锤脱离。
按照本发明提供的一种把颗粒骨料压制成板材的制备工艺与现有技术相比具有如下优点：本发明采用一种全新的制备工艺，其为“压力+拍击力”的组合方式，在成型过程中，压板始终与混合料不分离，压板始终存在于混合料上，拍击力只是针对压板施加，并使拍击力通过压板传导至混合料上。由于拍击力不是直接作用于混合料上，能够减少拍击力不均匀时对混合料造成损坏，减少裂纹的产生。并且，本发明的工艺能够满足薄板的加工要求，防止薄板在成型中拍击力直接作用于混合料上难以成型。
按照本发明提供的一种用于把颗粒骨料压制成板材的成型设备与现有技术相比具有如下优点：本发明的成型设备重锤拍击力只会产生对混合料的上下力，不会对混合料产生水平方向的侧向力；解决板材在成型压制过程中受力不均匀。本发明的重锤的拍击力也不会受到真空影响而减弱。
附图说明
图1是本发明的主视图。
图2是本发明的左视图。
图3是本发明的俯视图。
图4是本发明的立体图。
图5是本发明的正面剖视图。
图6是本发明的侧面剖视图。
图7是本发明重锤、模框和压板的剖视图。
图8是本发明中模框立体图。
图9是图6中A处放大图。
具体实施方式
为清楚的说明本发明中的方案，下面给出优选的实施例并结合附图详细说明。以下的说明本质上仅仅是示例性的而并不是为了限制本公开的应用或用途。应当理解的是，在全部的附图中，对应的附图标记表示相同或对应的部件和特征。
本发明提供的一种把颗粒骨料压制成板材的制备工艺，包括以下步骤，
A、配料，将不同粒径的颗粒骨料和液态物料按照比例混合，形成混合料；不同粒径的颗粒骨料和液态物料根据真空石的样式选择，并进行配比，比如采用石英石颗粒骨料，或者是其他的石材颗粒等。液态物料可以为液体填充剂。
B、布料，将混合料按照所需厚度平整的布置在输料带上或模框内；
C、真空处理，对混合料进行真空排气处理；
D、成型，在成型过程中，在混合料上覆盖一压板，所述压板始终施加一个向下的压力于混合料上，位于所述压板上方的拍击重锤连续拍击所述压板，在所述拍击重锤拍击的过程中，所述压板产生的压力对混合料形成持续的保持力，所述拍击重锤上下运动产生的拍击力经所述压板传导至混合料中，所述压板产生的压力和所述拍击重锤产生的拍击力叠加形成的复合力共同作用于混合料中，使混合料中的颗粒骨料在所述复合力的作用下互相运动填充，并将所述液态物料填充到各所述颗粒骨料的缝隙中，形成致密板材结构；
E、固化，对成型的板材结构进行固化，得到成品。
本发明在上述成型过程中，采用“压力+拍击力”组合方式进行成型，该种方式能够有效解决现有技术中“压振”和“单独拍击力”存在的问题。 在成型过程中，所述压板始终压紧混合料，防止混合料在拍击抬起时发生反弹，从而造成混合料难以成型，也能有效减少混合料产生裂纹。对于薄板的加工效果更好，薄板在成型过程中，由于拍击力直接作用于混合料上，混合料存在厚度不同等情形，拍击力会将混合料拍散，从而产生裂纹。本发明设置压板，使得拍击力间接作用于混合料上，减少了拍击力对混合料损坏，减少裂纹，提高成品率。
在本发明提供的上述实施例中进一步包括，所述拍击重锤产生的拍击力经所述压板均匀分布于混合料上。本发明中所述压板为一整板结构，能够将拍击力均匀分散，从而使得混合料受力均匀，不会产生聚料或跑料的问题，提高成板率。
在本发明提供的上述实施例中进一步包括，所述压板产生的压力包括压板自重力和真空产生的压力。本发明中的压板采用整块钢板制成，其具有足够大的重量，本身自重力能够满足“压力”需要。由于压板与混合料之间形成真空，大气压力也作用于压板上，使得压板进一步增大“压力”。当然，在本发明中所述压板产生的压力还可以是包括压板自重力、真空产生的压力和外部施加的压力。所述外部施加的压力可以是增加液压机构，对所述压板施加液压压力。当然，也可以增加气压机构，或者增加额外配重来提高压板产生的压力。本发明的上述结构使得混合料在成型过程中，始终有足够的压力保持特定状态，使得在所述拍击重锤抬起时，混合料不会发生反弹。
在本发明给出的上述实施例中进一步包括，所述拍击重锤在成型过程中处于自由无阻力状态。本发明中的拍击重锤位于真空腔外，工作过程中，不会受到真空力的影响。另外，本发明中的所述拍击重锤在工作过程中处 于悬空状态，能够产生足够大的拍击力。
参见图1至图9，在本发明给出的一种用于把颗粒骨料压制成板材的成型设备，包括基座1、安装在所述基座1上的拍击重锤2和驱动所述拍击重锤2的驱动器3，所述基座1上具有载料区，还包括一压板4，所述压板4覆盖在所述载料区上，所述拍击重锤2位于所述压板4的上方，在工作时，所述压板4始终施加一个向下的压力于所述载料区的混合料上，所述拍击重锤2连续拍击所述压板，所述压板4产生的压力对混合料形成持续的保持力，所述拍击重锤2上下运动产生的拍击力经所述压板4传导至所述载料区的混合料中，所述压板4产生的压力和所述拍击重锤2产生的拍击力叠加形成的复合力共同作用于所述载料区的混合料中。本发明在拍击重锤设备中增加压板结构，所述压板4为板状结构，其大小可以混合料一致，将整个混合料覆盖，本实施例中的压板4采用钢板制成，具有足够大的重量，从而产生的压力满足要求。在工作时，所述压板4始终压紧所述混合料，使得混合料不会发生反弹，利于混合料的快速成型，缩短成型时间。由于拍击力是间接作用于混合料上，混合料不会发生反弹，所述拍击重锤2可以采用更高的拍击频率，更高的拍击力，进一步提高混合料成型速度，缩短成型时间，提高生产效率。
参见图1至图9，在本发明给出的上述实施例中进一步包括，还包括一模框5，所述压板4的部分结构插入所述模框5中。所述模框5为金属制成的框架结构，对混合料起到限料作用，防止发生漏料或跑料。在工作时，所述压板4的至少部分结构位于所述模框5中。利于压紧位于模框5中的混合料。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述模框 5与所述基座1之间设置有密封结构51，所述模框5与所述压板4之间设置有密封机构52，所述模框5、所述基座1和所述压板4形成一容纳混合料的真空腔，所述真空腔与真空系统相连接。本发明的真空腔是由所述模框5、所述基座1和所述压板4形成，真空力可以进一步提高所述压板4产生的压力。所述拍击重锤2没有位于所述真空腔中，真空力不会对拍击重锤2造成影响，也就不会对拍击重锤2产生的拍击力减弱。所述密封结构51为安装在所述模框5底部的至少两圈密封圈，所述密封圈被压紧在所述基座1上。所述密封机构52为安装在所述模框5侧壁上的齿状密封圈，所述齿状密封圈顶靠在所述压板4的侧壁上。
参见图1至图9，在本发明给出的上述实施例中进一步包括，还包括一限位装置6，所述限位装置6顶靠在所述拍击重锤2的侧壁上。所述限位装置6为多组限位块，对所述拍击重锤2起到限位作用，防止拍击重锤2在拍击过程发生偏移，使其形成的拍击力是上下运动的拍击力。
参见图1至图9，在本发明给出的上述实施例中进一步包括，还包括一设置在所述模框5上的限位装置6，所述限位装置6顶靠在所述拍击重锤2的侧壁上。本实施例中的限位装置6是设置在模框5上，所述限位装置对所述拍击重锤2起到限位作用。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述限位装置6上设置有接触凸条61，所述接触凸条61由耐磨减震材料制成。所述接触凸条61起到支撑的作用，减少所述拍击重锤2的摩擦。所述限位装置6上成形有凹槽62，所述接触凸条61安装在所述凹槽62中。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述压板4上设置有悬挂件41，所述悬挂件41勾挂在所述拍击重锤2上，在工作时， 所述悬挂件41与所述压板4或所述拍击重锤2脱离。本发明中，所述拍击重锤2还设置有重锤液压缸21，所述重锤液压缸21为四组液压机构，能够将所述拍击重锤2抬升起来，在抬升过程中，所述悬挂件41能够将所述压板4一起抬起，从而使压板4与混合料分离，方便运料。当然，本发明中所述模框5也设置有模框液压缸53，所述悬挂件41也可以是与所述模框5相连接，从而在举升模框5，同时带动所述压板4。
参见图1至图9，在本发明给出的上述实施例中，多台所述驱动器3同步连接在一起，构成一组同步驱动组，所述拍击重锤2顶部设置有至少四组同步驱动组，每两组同步驱动组通过同步机构连接在一起。所述同步机构包括多个同步轮31和多个同步带32，相邻所述驱动器3之间的连接处安装所述同步轮31，所述同步轮31与所述驱动器3的转轴相连接。相邻两组同步驱动组中的同步轮31通过所述同步带32连接，从而实现相邻两组同步驱动组同步运行。本发明中同步机构是有多个同步轮和同步带构成，同步效果更好。本实施例为四组同步驱动组，两两同步，转动方向相反，为一正一反。这种结构同步效果更好。当然，本发明也可以将四组同步驱动组都通过同步轮和同步带连接在一起，实现四组同步。在本发明中，所述同步驱动组为六组时，则其中的三组同步，另外三组同步。即采用偶数设置，对半分开同步。所述同步轮31为带齿轮子，所述同步带32为带齿皮带。所述同步带32与所述同步轮31啮合，实现同步运行。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述模框5的中部成形有镂空部，所述模框5的侧边成形有翼板54，所述基座1上设置有模框液压缸53，所述模框液压缸53顶靠在所述翼板54上。所述模框5起到框料的作用，使得真空石混合料位于镂空部中，不会向四周漏料。 所述模框液压缸53用于驱动所述模框5升降，所述翼板54更加利于模框液压缸53的安装。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述基座1上设置有导柱15，所述翼板54上设置有导筒55，所述导柱15穿入所述导筒55中。所述导柱15和导筒55使得模框5的升降更加平稳。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述基座1上成形有台阶16，所述模框液压缸53和所述导柱15设置在所述台阶16上。设置所述台阶16方便模框液压缸53和导柱15安装和固定。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述拍击重锤2的上部侧边向外延伸形成突出部28，所述重锤液压缸21顶靠在所述突出部28。所述突出部28利于所述重锤液压缸21顶靠。
参见图1至图9，在本发明给出的上述实施例中进一步包括，所述基座1由多层板材叠合而成，所述基座1的重量大于所述拍击重锤2的拉力。本发明的基座1重量大，所述拍击重锤2在拍击过程中，其不会发生位移。
在本发明给出的上述工艺实施例和设备实施例中，两个实施例的相应内容可以相互引用。即设备实施例中内容用于工艺中，工艺实施例中的内容也可以用于设备中。
在本发明中，所述颗粒骨料在真空力、压力和重锤拍击力的合力作用下互相运动填充，并将所述液体填充剂填充到各所述颗粒骨料的缝隙中，形成真空密闭体，即为真空石。利用该设备可以将不同粒径的颗粒骨料相互填充，大粒径颗粒骨料相互接近贴合，小粒径颗粒骨料填充大粒径颗粒骨料之间的缝隙，各粒径颗粒骨料之间的缝隙由填充单元体填充，所述填充单元体在填充的过程中，其表面的柔性液体填充膜根据缝隙的大小形状 发生变形，从而尽可能将所有缝隙均填充密实，排出缝隙中的空气。本发明利用马德堡半球的原理制备出真空石，该真空石更接近于自然界中天然石材，真空石的整体性能也接近于天然石材。
本发明真空石的成型原理：现有技术中的合成石均是利用粘结剂将各粒径的颗粒骨料粘结在一起，不仅合成石的强度不高，而且不够环保。本发明的真空石是利用大气压强将各粒径颗粒骨料压在一起，强度更高，也更环保。本发明提出的填充概念是指各粒径颗粒骨料相互运动贴合，并由次一级粒径的颗粒骨料填充大一级粒径的颗粒骨料缝隙，最终由填充单元体完成所有缝隙的填充。本发明的填充工艺不同于现有技术中的压制工艺。本发明为了实现填充目的，各粒径颗粒骨料不与液体填充剂混合，各粒径颗粒骨料能够更好的相互贴合，也降低了液体填充剂的使用量。所述液体填充剂只与细粒径固体颗粒填充料混合，制成最小粒径的填充单元体，制备完成的所述填充单元体再用于颗粒骨料的混合，使所述填充单元体包裹各粒径的颗粒骨料，包裹填充单元体的颗粒骨料在成型过程中能够更好的相互填充，它们之间的缝隙则由填充单元体填充，最终形成真空密闭体。若各粒径颗粒骨料表面包裹粘结剂，则在压制过程中，细粒径颗粒骨料难以填充进颗粒骨料的缝隙中。粘结剂使用过多，在压制过程中，多余的粘结剂很难从合成石排出，最终形成的就是由粘结剂粘结形成的合成石结构，粘结剂的粘结强度决定了合成石的强度。同时，本发明也无需对真空石进行烧结，是一种免烧结制备工艺，更加环保。因此，本发明提出的制备工艺是一种全新工艺。
本发明中的填充单元体是将细粒径固体颗粒填充料与液体填充剂混合，使所述固体颗粒填充料的表面形成柔性液体填充膜；本发明中的细粒径固 体颗粒填充料为最小粒径填充单元，所述柔性液体填充膜具有外形可塑特性，在填充过程中能够根据缝隙的大小变化形状，从而适用大小不同的缝隙，将缝隙填充密实。
在本发明给出的上述实施例中进一步包括，所述固化是将所述液体填充剂由液态变为固态。本发明所述的液体填充剂是指具有由液态转化为固态特性的液体，这种液体还需要在常态情况下长期保持固态，从而消除缝隙中的空气，使空气不易进入缝隙中。所述液体填充剂可以具有由液态变为固态的特性，包括有机类树脂和无机类树脂。所述有机类树脂包括亚克力树脂、不饱和树脂、丙烯类树脂或环氧树脂，无机类树脂包括大豆基树脂或橡胶类树脂。这些液体填充剂具有由液体向固态转化的特性，并能够满足真空石的需要。本发明所述的液体填充剂是指具有由液态转化为固态特性的液体，这种液体还需要在常态情况下长期保持固态，从而消除缝隙中的空气，使空气不易进入缝隙中，比如上述的各种树脂等，这些树脂自身或在催化剂的作用下由液态转化为固态。
综上所述，以上所述内容仅为本发明的实施例，仅用于说明本发明的原理，并非用于限定本发明的保护范围。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (12)

  1. 一种把颗粒骨料压制成板材的制备工艺，包括如下步骤：
    A、配料，将不同粒径的颗粒骨料和液态物料按照比例混合，形成混合料；
    B、布料，将混合料按照所需厚度平整的布置在输料带上或模框内；
    C、真空处理，对混合料进行真空排气处理；
    D、成型，在成型过程中，在混合料上覆盖一压板，所述压板始终施加一个向下的压力于混合料上，位于所述压板上方的拍击重锤连续拍击所述压板，在所述拍击重锤拍击的过程中，所述压板产生的压力对混合料形成持续的保持力，所述拍击重锤上下运动产生的拍击力经所述压板传导至混合料中，所述压板产生的压力和所述拍击重锤产生的拍击力叠加形成的复合力共同作用于混合料中，使混合料中的颗粒骨料在所述复合力的作用下互相运动填充，并将所述液态物料填充到各所述颗粒骨料的缝隙中，形成致密板材结构；
    E、固化，对成型的板材结构进行固化，得到成品。
  2. 如权利要求1所述的一种把颗粒骨料压制成板材的制备工艺，其特征在于：所述拍击重锤产生的拍击力经所述压板均匀分布于混合料上。
  3. 如权利要求1所述的一种把颗粒骨料压制成板材的制备工艺，其特征在于：所述压板产生的压力包括压板自重力和真空产生的压力。
  4. 如权利要求1所述的一种把颗粒骨料压制成板材的制备工艺，其特征在于：所述压板产生的压力包括压板自重力、真空产生的压力和外部施加的压力。
  5. 如权利要求1所述的一种把颗粒骨料压制成板材的制备工艺，其特征在于：所述拍击重锤在成型过程中处于自由无阻力状态。
  6. 一种用于把颗粒骨料压制成板材的成型设备，包括基座、安装在所述基座上的拍击重锤和驱动所述拍击重锤的驱动器，所述基座上具有载料区，其特征在于：还包括一压板，所述压板覆盖在所述载料区上，所述拍击重锤位于所述压板的上方，在工作时，所述压板始终施加一个向下的压力于所述载料区的混合料上，所述拍击重锤连续拍击所述压板，所述压板产生的压力对混合料形成持续的保持力，所述拍击重锤上下运动产生的拍击力经所述压板传导至所述载料区的混合料中，所述压板产生的压力和所述拍击重锤产生的拍击力叠加形成的复合力共同作用于所述载料区的混合料中。
  7. 如权利要求6所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：还包括一模框，所述压板的部分结构插入所述模框中。
  8. 如权利要求7所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：所述模框与所述基座之间设置有密封结构，所述模框与所述压板之间设置有密封机构，所述模框、所述基座和所述压板形成一容纳混合料的真空腔，所述真空腔与真空系统相连接。
  9. 如权利要求6所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：还包括一限位装置，所述限位装置顶靠在所述拍击重锤的侧壁上。
  10. 如权利要求7所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：还包括一设置在所述模框上的限位装置，所述限位装置顶靠在所述拍击重锤的侧壁上。
  11. 如权利要求9或10所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：所述限位装置上设置有接触凸条，所述接触凸条由耐 磨减震材料制成。
  12. 如权利要求6所述的一种用于把颗粒骨料压制成板材的成型设备，其特征在于：所述压板上设置有悬挂件，所述悬挂件勾挂在所述拍击重锤上，在工作时，所述悬挂件与所述压板或所述拍击重锤脱离。
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