Process for manufacturing agglomerated stone slab

Abstract

The process of the invention presents a simple, effective and continuous process for producing slabs and panels from compositions free from ceramic components or ceramic binders.

Claims

1. A process for manufacturing an agglomerated stone slab, the process comprising: sintering a mixture comprising a glass binding phase, wherein the glass is not soda lime glass; and a bulk matrix of granulates of agglomerated stone having particles of an average size between 0.1 and 1.5 mm, wherein the maximum particle size is consistent with a thickness of a final compacted agglomerated stone slab; wherein a ratio between the binding phase to the bulk matrix is between 0.34 to 0.55 by volume; and wherein said sintering is carried out at a temperature of between 450° C. and 700° C. to obtain the agglomerated stone slab, wherein said mixture contains no ceramic materials.

2. The process according to claim 1, wherein said bulk matrix include at least one natural material selected from quartz, granite, porphyry, syenite, basalt, sandstone and sand.

3. The process according to claim 1, wherein said glass is in a form of at least one of glass powder and glass frits.

4. The process according to claim 1, further comprising compacting the mixture to form a green-body.

5. The process according to claim 4, wherein said compacting includes applying a pressure of at least 0.5 kg/sq. cm.

6. The process according to claim 1, wherein said agglomerated stone slab is characterized by a water absorption of less than 0.01%.

7. The process of claim 1, further comprising: compacting the mixture prior to said sintering utilizing vibro-compression.

8. The process of claim 7, wherein said compacting is onto a molding support, the process further comprising: molding said mixture into a form of a plate prior to said sintering.

9. The process of claim 1, further comprising: adding an additive selected for at least one property from the group consisting of plasticizing the mixture, stabilizing the mixture, remaining solid at the working point temperature, undergoing a phase change at temperature of said sintering, undergoing a reaction with at least one other component in the mixture during processing, and undergoing decomposition or degradation, thereby leaving behind a vacancy or pore in the mixture.

10. The process of claim 1, further comprising: adding to said mixture a reinforcing material that remains solid at the temperature of said sintering.

11. The process of claim 10, wherein said reinforcing material includes an inorganic fiber.

12. The process of claim 10, wherein said reinforcing material is transparent.

13. The process of claim 1, further comprising: spray drying the mixture prior to said sintering.

Description

DETAILED DESCRIPTION OF EMBODIMENTS

(1) The following are non-limiting examples of certain embodiments of the present invention.

EXAMPLE 1

(2) Mixture for the production of slabs,processing temperatures between 750 and 930° C.:

(3) TABLE-US-00001 Glass (glaze compositions) 35% Sand (grain 0.4-0.8 mm) 45% Sand (grain 0.1-0.3 mm) 15% Fiber (Reinforcing additive)  2% Technological additives  3%

EXAMPLE 2

(4) Mixture for the production of slabs, processing temperatures between 600 and 750° C.:

(5) TABLE-US-00002 Glass (low-melting glass compositions) 30% Aggregate (grain 2.5-5 mm) 15% Aggregate (grain 1.5-2.5 mm) 15% Aggregate (grain 1-1.5 mm) 10% Aggregate (grain 0.4-0.8 mm) 10% Aggregate (grain 0.1-0.3 mm) 15% Fiber (Reinforcing additive)  2% Technological additives  3%

EXAMPLE 3

(6) The mixture of Example 1 above was utilized in the manufacture of a slab, without mechanical treatment of the slab upper surface for the purpose of decorating this surface for a final product.

EXAMPLE 4

(7) The mixture of Example 2 above was utilized in the manufacture of a slab. which was further dressed and polished. This product was characterized with a high aesthetical properties, e.g., having better optical characteristics.