ES1290469U - Equipment and process for the manufacture of slabs made of ceramic and/or stone material - Google Patents

Abstract

The equipment (1) for the manufacture of slabs made of ceramic and/or stone material, comprises at least one mould (2), adapted to be positioned resting on a supporting surface (3) and defining with the latter at least one collecting cavity (4,5) of at least one ceramic and/or stone material intended to be deposited on the supporting surface (3) to obtain at least one slab to be compacted (C), where the mould (2) comprises at least one inner wall (2b) adapted to divide the collecting cavity (4,5) into at least a first cavity (4), adapted to contain at least a first type of ceramic and/or stone material (Ml), and at least a second cavity (5) adapted to contain at least a second type of ceramic and/or stone material (M2).

Description

EQUIPMENT FOR THE MANUFACTURE OF SLABS MADE OF CERAMIC AND/OR STONE MATERIAL

technical field

The present invention relates to equipment and a method for the manufacture of slabs made of ceramic and/or stone material.

Background art

It is well known how in many sectors of industrial activities there is a particular need to renew manufactured products and to look for new ones to better distinguish them from those of the competition.

This need exists, in particular, in the industry dealing with the production of slabs made of ceramic and/or stone material used for the manufacture of, for example, floors and/or walls.

Today the market increasingly requires special aesthetic effects, such as the reproduction of natural rocks, such as marble or granite, characterized by the presence of "veins", that is, stripes of a different color compared to the base material, which have an irregular pattern and run through the entire thickness of the material.

The manufacture of slabs made of ceramic and/or stone material, such as slabs of mineral grit bonded with resins, generally entails a phase of deposition of a base material, which can consist of ceramic materials or a mixture of mineral compounds in the form granular (for example, marble, granite), glass, mirror fragments, quartz powder, etc., as well as resins that act as binders, on a supporting surface, such as a tape or a mold, to form a slab that will be compacted, and a subsequent pressing phase, to obtain a compacted slab.

Depending on the type of mixture, additional phases are then carried out, such as, for example, cooking and subsequent cooling, to obtain a product with special mechanical and physical properties.

Therefore, the equipment necessary to carry out these phases implies the presence of dispensing means to dispense the base material on a support surface, to form a slab to be compacted, and pressing means to obtain a compacted slab.

As the technician of the sector knows, depending on the type of materials used, the embodiments and the technical characteristics of the devices that form the relevant equipment may vary.

A type of known equipment includes the use of a hopper that extends over the entire width of the slab to be obtained and inside which the ceramic materials that will be deposited on an extraction surface are loaded, since there is a movement between the latter and the hopper itself.

In order to obtain particular chromatic effects, such as, for example, a "grained" effect, a plurality of materials of different types are deposited inside the hopper, which are stratified inside the hopper and then successively deposited on the surface. of extraction.

As a result of the friction of the material on the walls of the hopper, the flow of material out of the hopper is irregular and random, so the intensity of the color of the veins obtained is nuanced or imprecise.

In addition, the ceramic material that comes out of the hopper, which comes into contact with the terminal portion of the walls, is partially dragged on the surface of the slab with a consequent alteration of the desired aesthetic effect.

Last but not least, the slab thus obtained has surface veins that do not go through the entire thickness of the slab itself.

Known-type processes therefore prevent obtaining the so-called "through veins", typical of natural rocks.

This drawback is particularly evident in the case of slabs that have to be made with two orthogonal surfaces, as is the case with countertops for kitchens, bathrooms or other similar applications, for which it is not possible to obtain a substantially continuous grain throughout. the two orthogonal surfaces.

Description of the invention

The main objective of the present invention is to conceive an equipment and a procedure for the manufacture of slabs made of ceramic and/or stone material that allows a wide variety of aesthetic effects to be obtained in a simple and reliable manner.

Within this objective, an object of the present invention is to make aesthetic variants distinguished by colors and/or designs that cannot be obtained using the natural materials mentioned above, and at the same time reproduce as faithfully as possible the typical grained effect of rocks. natural, thus allowing a particularly versatile and customizable production.

An additional object of the present invention is to conceive equipment and a method for the manufacture of slabs made of ceramic and/or stone material that are highly repeatable and allow to obtain slabs with the same aesthetic effect over time.

Another object of the present invention is to conceive an equipment and a method for the manufacture of slabs made of ceramic material and/or stone that allow to overcome the drawbacks of the prior art mentioned above in a simple, rational, easy, effective use solution. and low cost.

The objects mentioned above are achieved by the present equipment for the manufacture of slabs made of ceramic and/or stone material having the features of claim 1.

The objects mentioned above are also achieved by the present process for the manufacture of slabs made of ceramic and/or stone material having the features of claim 15.

Brief description of the drawings

Other characteristics and advantages of the present invention will be more evident from the description of a preferred, but not exclusive, embodiment of an equipment and a procedure for the manufacture of slabs made of ceramic material and/or stone, illustrated by way of indicative example, but not restrictive, in the attached tables of drawings, where:

Figures 1-5 are schematic representations of a first embodiment of the equipment and the method for the manufacture of slabs made of ceramic and/or stone material according to the invention;

Figures 6-7 are schematic representations of a second embodiment of the equipment and method according to the invention.

Embodiments of the invention

With particular reference to these figures, the reference number 1 globally indicates equipment for the manufacture of slabs made of ceramic and/or stone material.

In the context of the present discussion, the expression "ceramic and/or stone material" means a material of ceramic type, in the form of atomized grains or flakes, and/or stone material, such as marble, granite, minerals or other natural stones, in the form of powder and/or granules and/or flakes, and mixed with a binder of a cementitious or resinous nature.

The equipment 1 comprises at least one mold 2 adapted to be placed resting on a support surface 3.

The mold 2 is provided with a plurality of perimeter walls 2a that define a closed profile.

Preferably, the mold 2 has a substantially rectangular shape and the perimeter walls 2a define a lower opening, intended to come into contact with the support surface 3, and an upper opening, opposite the lower opening.

The mold 2 defines with the support surface 3 at least one cavity 4,5 for collecting at least one ceramic and/or stone material intended to be deposited on the support surface 3 to obtain at least one slab that will be compacted C.

In other words, the collection cavity 4,5 is delimited below by the support surface 3 and laterally by the perimeter walls 2a, while communicating with the outside through the upper opening of the mold 2 through which insert the ceramic and/or stone material inside.

As shown in Figure 2, the support surface 3 is movable along a forward movement direction A.

The support surface 3, for example, is of the type of a conveyor belt or the like.

However, additional embodiments where the support surface 3 is of the fixed type cannot be ruled out.

According to the invention, the mold 2 comprises at least one internal wall 2b adapted to divide the collection cavity 4,5 into at least one first cavity 4, adapted to contain at least one first type of ceramic and/or stone material M1, and at least one second cavity 5, adapted to contain at least one second type of ceramic and/or stone material M2.

In other words, the internal wall 2b generates a compartmentalization of the collection cavity 4,5 that allows the deposition of different materials inside the two cavities 4 and 5.

The two types of materials M1 and M2 differ from each other for at least one of the grain size, color and composition of the ceramic and/or stone grits.

Conveniently, the at least one internal wall 2b is curvilinear, to create an aesthetic effect in the finished slab very similar to what is found in natural rocks.

The at least one internal wall 2b extends from one of the perimeter walls 2a of the mold 2, to reach another of the perimeter walls 2a.

In particular, the inner wall 2b extends from one of the perimeter walls 2a to reach the opposite perimeter wall 2a.

In other words, the inner wall 2b passes through the mold 2.

As shown in the figures, the mold 2 comprises at least one pair of internal walls 2b spaced apart from each other.

In particular, the volume placed between the internal walls 2b defines the second cavity 5 and the first cavity 4 is located on opposite sides of the second cavity 5 with respect to the internal walls 2b.

Conveniently, the inner walls 2b are substantially parallel to each other.

The mold 2 also comprises one or more support elements 6 placed between the internal walls 2b and at least one of the perimeter walls 2a.

The support elements 6 have the function of supporting the internal walls 2b so that the cavities 4 and 5 do not undergo deformation due to mechanical stress during the manufacture of the slab.

More particularly, the support elements 6 are housed within the first cavity 4.

The equipment 1 also comprises dispensing means 7,8 adapted to deposit a plurality of ceramic and/or stone materials on the support surface 3.

In more detail, the dispensing means 7,8 deposit the ceramic and/or stone material inside the collection cavity 4,5.

Suitably, the equipment 1 comprises first means 7 for dispensing the first type of material M1, which are adapted to deposit the first type of material M1 inside the first cavity 4.

In the embodiment shown in the figures, the first dispensing means 7 are of the hopper type.

The equipment 1 also comprises second means 8 for dispensing the second type of material M2, which are adapted to introduce the second type of material M2 into the second cavity 5.

The second dispensing means 8 is conveniently arranged upstream of the first dispensing means 7 along the direction of forward movement A.

With reference to the embodiment shown in Figures 1 to 5, the second dispensing means 8 comprise at least one dispensing element 9 movable with respect to the mold 2 for dispensing the second type of material M2 inside the second cavity 5.

In more detail, the dispensing element 9 is movable along a dispensing direction E which is substantially parallel to the support surface 3 and transverse to the direction of forward movement A.

In this way, the movement of the mold 2 along the forward movement direction and of the dispensing element 9 along the dispensing direction E allows filling the second cavity 5 following the pattern of the internal walls 2b.

In an alternative embodiment of the present equipment, shown in Figures 6 and 7, the support elements 6 are of the tubular type and define a passage adapted to connect the second cavity 5 to the outside.

Specifically, the passageway defines a communication hole 10 communicating with the outside and facing the relevant perimeter wall 2a.

This embodiment requires that the second dispensing means 8 comprise at least one injection element 11 connectable to at least one of the support elements 6 to inject the second type of material M2 into the second cavity 5.

In particular, the injection element 11 can be associated with the communication hole 10.

After the materials M1 and M2 have been dispensed, the mold 2 is then removed from the support surface 3, thus defining a slab to be compacted C placed resting on the support surface 3.

Suitably, the equipment 1 comprises smoothing means 12 adapted to level the materials M1 and M2.

As shown in the figures, the smoothing means 12 may comprise a roller device 13, arranged downstream of the first dispensing means 7, which are capable of leveling the surface of the slab to be compacted C while the surface of holder 3 slides along the forward movement direction A.

This embodiment provides that the leveling is carried out as a result of the removal of the mold 2.

Alternatively or in combination with it, the smoothing means 12 can be associated with the first dispensing means 7 and perform the leveling operation at the same time as the deposition of the first type of material M1 inside the mold 2.

Lastly, the equipment 1 comprises pressing means, not shown in detail in the figures, and adapted to press the slab that will be compacted C to obtain a slab of ceramic and/or stone material.

The pressing means are of a type known to those skilled in the art and will not be described in the present discussion.

The operation of equipment 1 in the method according to the invention is as follows.

The method comprises, firstly, supplying at least one first type of ceramic and/or stone material M1 and at least one second type of ceramic and/or stone material M2, different from the first type of material M1.

The method also comprises the supply of at least one mold 2 defining a closed profile.

The mold 2 is placed on the support surface 3 in such a way that it defines with it at least one collection cavity 4,5, where the mold 2 comprises at least one internal wall 2b adapted to divide the collection cavity 4,5 in at least one first cavity 4 and at least one second cavity 5.

The method comprises the deposition of the first type of material M1 inside of the first cavity and the introduction of the second type of material M2 inside the second cavity 5.

Preferably, the deposition of the first type of material M1 is carried out after the introduction of the second type of material M2.

In the embodiment of the equipment 1 described above, the mold 2 moves along the forward movement direction A by means of the support surface 3.

The method therefore comprises the introduction of the second type of material M2 inside the second cavity 5 by means of the second dispensing means 8.

In particular, with reference to the embodiment shown in Figures 1 to 5, the introduction of the second type of material M2 is carried out by means of the dispensing element 9, which, by moving with respect to the support surface 3, dispenses the material inside the second cavity 5 after the extension of the internal walls 2b.

In the embodiment shown in Figures 6 and 7, on the contrary, the introduction of the second type of material M2 is carried out by means of at least one injection element 11, suitably connected to a respective communication hole 10, which dispenses the material inside the second cavity 5 through the passages defined in the support elements 6.

Subsequently, the first type of material M1 is deposited inside the first cavity 4.

More particularly, in the embodiment shown in the figures, the mold 2 containing the second type of material M2 moves by means of the support surface 3 to the first dispensing means 7, where the deposition of the first type of material M1 is carried out. takes place within at least the first cavity 4.

At this point, the mold is removed from support surface 3 to obtain the slab to be compacted C, which is placed resting on support surface 3.

The slab to be compacted C continues along the forward movement direction A and is then pressed using the pressing means.

The method conveniently comprises a leveling phase of the materials M1 and M2 before pressing.

The leveling phase is carried out by the smoothing means 12.

In particular, the leveling can be carried out by means of the roller device 13, after extraction from the mold 2, and/or by the first dispensing means 7, during the deposition of the first type of material M1.

The leveling of the materials M1 and M2 makes it possible to obtain a slab that will be compacted C with a substantially uniform surface in order to optimize the pressing phase.

In practice, it has been determined that the described invention achieves its intended objectives and, in particular, it is underlined that the equipment and method according to the invention allow a wide variety of aesthetic effects to be obtained in a simple and reliable manner and, in particular, to obtain slabs provided with aesthetic variants distinguished by colors and/or designs that cannot be obtained using the natural materials mentioned above, thus allowing a particularly versatile and customizable production.

Furthermore, the equipment and the method according to the invention make it possible to obtain slabs that reproduce as faithfully as possible the chromatic effect of natural rocks.

Claims (14)

1) Equipment (1) for the manufacture of slabs made of ceramic and/or stone material, comprising at least one mold (2), adapted to be placed resting on a support surface (3) and defining with the latter at least one collection cavity (4,5) of at least one ceramic and/or stone material intended to be deposited on said support surface (3) to obtain at least one slab that will be compacted (C), characterized by the fact that said mold (2) comprises at least one internal wall (2b) adapted to divide said collection cavity (4,5) into at least one first cavity (4), adapted to contain at least one first type of ceramic material and/or stone (M1), and at least one second cavity (5) adapted to contain at least a second type of ceramic and/or stone material (M2). 2) Equipment (1) according to claim 1, characterized in that said at least one internal wall (2b) is curvilinear. 3) Equipment (1) according to one or more of the preceding claims, characterized in that said at least one internal wall (2b) extends from one of the perimeter walls (2a) of said mold (2). 4) Equipment (1) according to one or more of the preceding claims, characterized in that said mold (2) comprises at least one pair of said internal walls (2b) separated from each other, defining the volume placed between said internal walls (2b) said second cavity (5), said first cavity (4) being located on opposite sides of said second cavity (5) with respect to said internal walls (2b). 5) Equipment (1) according to one or more of the preceding claims, characterized in that said internal walls (2b) are substantially parallel to each other. 6) Equipment (1) according to one or more of the preceding claims, characterized in that said mold (2) comprises one or more support elements (6) placed between said internal walls (2b) and at least one of said perimeter walls (2a). 7) Equipment (1) according to claim 6, characterized in that said support elements (6) are housed inside said first cavity (4). 8) Equipment (1) according to claims 6 or 7, characterized in that said support elements (6) are of the tubular type and define a passage that is adapted to connect said second cavity (5) to the outside, defining said passage a communication hole (10) that communicates with the outside and that is oriented towards the relative perimeter wall (2a). 9) Equipment (1) according to one or more of the preceding claims, characterized in that it comprises first dispensing means (7) of said first type of material (M1). 10) Equipment (1) according to the preceding claim, characterized in that said first dispensing means (7) are of the hopper type. 11) Equipment (1) according to claims 9 or 10, characterized in that it comprises second dispensing means (8) of said second type of material (M2). 12) Equipment (1) according to the preceding claim, characterized in that said second dispensing means (8) comprise at least one dispensing element (9) movable with respect to said mold (2) to dispense said second type of material (M2) inside said second cavity (5). 13) Equipment (1) according to claims 8 and 11., characterized in that said second dispensing means (8) comprise at least one injection element (11) connectable to at least one of said support elements (6) to inject said second type of material (M2) into said second cavity (5), said injection element (11) being associable with said communication hole (10). 14) Equipment (1) according to one or more of the preceding claims, characterized in that said support surface (3) is mobile along a forward movement direction (A), said second dispensing means being (8) disposed upstream of said first dispensing means (7) along said forward movement direction (A).