STRATIFIED AND AGGLOMERATED ARTIFICIAL STONE ARTICLE

Abstract

The present invention relates to those articles that include any kind of agglomerated artificial stone and polymerisable resin, such as tiles or slabs, to be used as construction material, characterised for consisting of different strati or veins, of heterogeneous variable mass that provide a special aesthetic effect similar to the natural stone products.

Claims

1-14. (canceled)

15. A process for making stone, comprising: making a first mass, comprising: crushing a first material for a first filler, and mixing a first resin with the first filler; making a second mass, comprising: crushing a second material for a second filler, and mixing a second resin with the second filler; conveying the first mass towards a mold; conveying the second mass to the mold; downloading to the mold, in a predetermined order for a desired design of the stone, the first mass and the second mass; and applying pressure to the combination of the first mass and the second mass in the mold; hardening the combination of the first mass and the second mass.

16. The process according to claim 15, wherein the step of applying pressure comprises vacuum vibro-compression.

17. The process according to claim 15, wherein the step of hardening comprises polymerization of the resins by heating.

18. The process according to claim 17, further comprising cooling, sizing, polishing and cutting the hardened and molded combination of the first mass and the second mass.

19. The process according to claim 15, wherein the first filler has a first granulometry and the second filler has a second granulometry.

20. The process according to claim 15, wherein the first mass differs from the second mass in at least one of granulometry, pigmentation, or composition of material.

21. The process according to claim 20, comprising making one or more additional masses, each additional mass differing from the other in at least one of granulometry, pigmentation, or composition of material; and downloading to the mold, in a predetermined order for the desired a design of the stone, each of the additional masses.

22. The process according to claim 15, wherein the steps of conveying comprise conveying the first mass and the second mass on a conveyor belt and in a predetermine order corresponding to the predetermined order for downloading to the mold the first mass and the second mass.

23. The process according to claim 22, wherein a predetermined amount of the first mass and a predetermined amount of the second mass are placed on the conveyor belt in the predetermined order, the predetermined amounts and order of placement determining a strata of the first mass and the second mass in the stone.

24. The process according to claim 15, wherein the step of mixing the first resin with the first filler also comprises mixing a catalyser, an accelerant, and a binding material with the first filler.

25. The process according to claim 24, wherein the step of mixing the second resin with the second filler also comprises mixing a catalyser, an accelerant, and a binding material with the second filler.

26. The process according to claim 15, wherein the stone is in the form of a tile or slab.

27. The process according to claim 15, wherein the first resin is the same as the second resin and the first catalyzer is the same as the second catalyzer.

28. The process according to claim 15, wherein first mass and the second mass each define a distinct stratum within the stone.

29. The process according to claim 15, wherein, following the hardening step, the stone has veins with widths of between 10 to 3400 mm and lengths of between 100 to 3400 mm.

30. The process according to claim 15, wherein the first material and the second material comprise one or more of marble, dolomite, opaque quartz, clear quartz, silica, crystal, mirror, cristobalite, granite, albite, basalt and ferrosilicon.

31. The process according to claim 28, wherein a composition and granulometry in each stratum contains: 10% to 70% of micronized filler, with a granulometry between 0.1 m to 0.75 mm; 0% to 80% of crushed filler, with a granulometry between 0.76 mm and 1.20 mm; and 0% to 50% of crushed filler with a granulometry between 1.21 mm and 15 mm.

32. The process according to claim 15, wherein the first resin and the second resin are thermosetting polymerization resins selected from the group consisting of unsaturated polyester resin, methacrylate resin, epoxy resin, unsaturated polyester, vinyl resins.

33. The process according to claim 28, wherein each resin is part of a total mix of each stratum in a percentage between 6% and 30% in weight.

34. The process according to claim 28, wherein each resin is part of a total mix of each stratum in a percentage between 7% and 20% in weight.

Description

DESCRIPTION OF THE DRAWINGS

[0042] Drawing 1 represents a cross-wise cut of the feeding mechanism with a certain distribution of the different strati according to the present invention.

[0043] Drawing 2 represents the effect achieved in the final product from the distribution of the strati of drawing 1.

[0044] Drawing 3 represents another design of the stratified article where there are different granulometries in the different strati.

[0045] Drawing 4 represents a slab with vein effect according to the state of the art.

DETAILED DESCRIPTION AND PREFERRED PERFORMANCE METHOD OF THE INVENTION

[0046] The goal of the present invention is, then, the achievement of a stratified agglomerated product that is capable of overcoming the technical limitations in that related to the width and length of the veins in the products currently known in the state of the art and to its controlled disposition in the core of the product. When increasing the dimension of the veins, a stratified effect is achieved in the final product which has an even more natural look.

[0047] So, object of the present invention are the articles such as tiles and/or slabs made of artificial stone that have veins built by strati of different masses, these being created by fillers of different granulometry and the corresponding polymerisable resin and also additives, characterised because the veins present a width from 10 to 3400 mm, preferably, 500 mm, and length from 100 to 3400 mm, preferably, 1700 mm.

[0048] To the effects of the present invention, the use of natural and artificial materials of variable granulometry is considered which will be part of the fillers, amongst others: marble, dolomite, opaque quartz, clear quartz, silica, crystal, mirror, cristobalite, granite, albite, basalt, ferrosilicon, etc. It also considers the use of other filler materials such as: colour plastics, metals, woods, graphite, etc. The said materials are part of the different strati, preferably with the following composition and granulometry: [0049] 10% to 70% of micronized filler, with a granulometry between 0.0001 mm to 0.75 mm; [0050] 0% to 80% of crushed fillers, named crushed 1, with a granulometry between 0.76 mm and 1.20 mm; and optionally, [0051] 0% to 50% of crushed fillers, named crushed 2 with a granulometry between 1.21 mm and 15 mm.

[0052] The proportions of the different fillers are calculated in % of weight over the total weight that includes the fillers and the resin in the stratus.

[0053] The percentage of each granulometry in each stratus depends of the design of the slab to be achieved, modifying such percentages depending on the final result to be achieved.

[0054] The resin that is part of the paste is preferably unsaturated polyester resin; even if it also considers the use of other polymerisable and thermosetting resins such as: methacrylate resin, epoxy, unsaturated polyester, vinyl, etc.

[0055] The resin is part of the total mix of each stratus in a percentage between a 6% and a 30% of weight, being the percentage selection preferably between 7 and 20%.

[0056] Other additives that are part of the fillers are the catalyser, the accelerant, the binding product and, optionally, the colouring agent.

[0057] So, the process of the present invention, designed to get the stratified artificial stone products consists of the following stages: [0058] a) Crushing stage of the different materials with varied granulometry making up the fillers; [0059] b) Obtaining by the addition and mix of the stage that contains the resin with the catalyser, the accelerant, the binding material and, optionally the colouring agent; [0060] c) Mix of the products of the stages a) and b) until the homogenization and achievement of at least two pastes or masses of different granulometry. This process shall be independently made as many times as number of masses or pastes to be achieved. Each mass or paste, hereinafter called stratus, can be differentiated from the other thanks to its composition (granulometry, pigmentation, etc.) [0061] d) Transportation of the different strati by a conveyor belt to the feeding or distribution mechanism. This download implies the ordered placing of the different strati in an independent manner and depending on the final design that is to be achieved. For this, the different strati are downloaded in the feeding or distribution mechanism, one after the other and in a certain amount [0062] e) Download of the strati, placed in an ordered manner in the previous stage, from the distributor to the mould which creates the design and dimension of the slab. [0063] f) Protecting the mass that makes up the slabs with Kraft-type paper, or an elastomer, similar to a rubber coating [0064] g) Moulding and compressing of the paste in each mould by vacuum vibro-compression; [0065] h) Hardening by polymerization of the resin by heating [0066] i) Finish with a cooling, sizing, polishing and cutting stage

[0067] The process starts with the stage a) where the starting material is prepared being crushed until achieving the desired granulometry, mixing the different percentages of each granulometry and then downloading it in the planetary mixers.

[0068] The preparation of different compositions of fillers with variable granulometry, which will be, in the end, the different homogenised pastes that are part of the strati of the final product is considered. In general, and for the creation of the products included in the present invention, at least two different compositions of masses with fillers of variable granulometry have to be prepared, even if, pending on the final product to be achieved, the preparation of up to 20 different compositions of masses with fillers of different granulometry is considered.

[0069] These different fillers are distributed in different mixers with the possibility that each one of them receives the optional addition of a solid colouring agent or pigment.

[0070] If the colouring agent is liquid, it is added in the resin stage.

[0071] In the stage b) the preparation of the additivated resin is made with the catalyser and the accelerant. This catalyzer can be any that creates free radicals, known from the state of the art. The peroxides and peroxidicarbonates are those preferred. They can be presented in powder (for example, dilauryl perioxide or di-(4-ter-butil-ciclohexile) peroxi-di-carbonate or a mixture of both, or liquid (for example, tert-butyl perbenzoate or tert-butyl peroxi-2-ethyilhexanoate or a mixture of both).

[0072] The accelerant can be a cobalt composed derived from caprylic acid, for example, cobalt octoate at 6%, a binding product and optionally the colouring agent.

[0073] The proportion of this resin in the composition of each paste shall be established by the composition of each stratus, being the resin percentage between a 6% and a 30% in weight, being, preferably, the selection of a percentage of between 7 and 20%.

[0074] The stage c), means, as previously stated, obtaining different masses, pastes or strati which are independently prepared in each mixer and always avoiding a later homogenization existing in the regular processes.

[0075] During stage d) the different strati are transported in a conveyor belt from the mixers to the feeding or distributing mechanism, where they are placed or deposited, in a certain order, sequence or amount desired. If drawing 1 is checked, where two different strati have been prepared (mass 1 and mass 2), these have been downloaded on the feeding system following this frequency: mass 2, mass 1, mass 2, mass 1, mass 2 and mass 1.

[0076] Considering performing a controlled download of the strati in the feeding or distribution mechanism in an ordered manner with the volume and amounts desired, the device includes weighting means, such as, belts or hoppers which allow defining and controlling the amount of paste that will create a stratus in the final product.

[0077] Additionally, the device includes means that allow performing a download in movement of the different pastes in the feeding or distribution mechanism in a way that the speed and trajectory of the movement can be controlled to achieve a design of each stratus in the final product. As the paste download is continuous, and thanks to the fact that the movement of the feeding system can be controlled, the strati can be downloaded in a heterogeneous and controlled manner. This is, the closer the feeding system gets to the stratus downloading area, more paste is downloaded and, as it moves further away, the amount is reduced. This swinging movement of the feeding system will allow drawing a strati design like that shown in the example in Drawing 1 where a certain tilt has been included in the strati setting in the feeding system. The combination of the weighting and movement means allows controlling the strati dimensions, for example, width, length, shape, etc. in the final product.

[0078] Next, in stage e), the groups of strati made and present in the feeding mechanism are downloaded so they will be distributed along the pressed mould to achieve a stratified final product in all the dimensions of the slab, this is, visible strati both in the upper and lower surface, as in the laterals. The download over the mould can be made in two different ways: [0079] 1. By a belt over where the strati coming from the feeding system have been downloaded. [0080] 2. Directly placing the exit of the feeding system over the mould and downloading the stratus from the conveyor belt directly to the mould.

[0081] Once the strati are distributed in the mould stages f), g), h) and i) take place which are regular and known for the state of the art.

[0082] So, the mould with the strati is protected with a paper or rubber. Once the mixture is protected and placed in the mould, it is taken to a vacuum vibro-compression press, which is in charge of squeezing and compressing the material but first it has to pass by a vacuum and then the material is squeezed by vibro-compression, following the method designed and described by the Italian company Breton SPA., as described in the U.S. Pat. No. 4,698,010.

[0083] The pressed tile is driven to an oven that is at a temperature between 80 C. and 110 C. for the resin to polymerise. The time of stay of each slab in the oven is from 30 to 60 minutes.

[0084] Once outside the oven, the slab is cooled for about 24 hours at room temperature in order to, later, calibrate, polish and cut it.

[0085] As final results, there is a slab with a stratified effect existing in all of its dimensions where the strati (which can be considered as big size veins) have a width and length of greater dimensions than the products existing in the state of the art. Thus, the final design is going to depend both of the shape, colour and granulometry of the materials that create the pastes or strati, as of the design provided with the different systems described in the present invention, achieving a petrous agglomerate with a more natural look, with more movement, more depth and a controlled stratified effects in all the dimensions of the product.

EXAMPLES

Example 1

[0086] Crushing in mills of the starting material until achieving the desired granulometry to finally get the filler material with the following granulometry distribution: [0087] Crushed filler 1 of granulometry between 0.76-1.2 mm [0088] Crushed filler 2 of granulometry between 1.21-15 mm [0089] Micronized filler of granulometry between 0.05-0.75 mm

[0090] Now the crushed filler 1 and micronized filler are added to a planetary mixer where they are mixed with the resin, the catalyser, the accelerant and the colouring agent, in the following proportions to build paste 1:

[0091] 69% crushed filler 1, 20% micronized filler, 11% resin, (% calculated over the total weight of the fillers and resin mixture)

[0092] 0.2% of accelerant in proportion to the resin amount

[0093] 2% of binding material in proportion to the resin amount

[0094] 2% of catalyser in proportion to the resin amount

[0095] 4% of black colouring agent in proportion to the resin amount

[0096] Mixture starts until homogenization and obtaining the first paste which will be transported by a conveyor belt to the feeding mechanism.

[0097] Simultaneously, the crushed filler 1, crushed filler 2 and micronized filler are added in a planetary mixer where the catalyser, the accelerant, the binding and the colouring agent are mixed with the resin in the following proportions to achieve mass 2.

[0098] 34% crushed filler 1, 40% crushed filler 2, 17% micronized filler, 9% resin, (% calculated over the total weight of the fillers and resin mixture)

[0099] 0.2% of accelerant in proportion to the resin amount

[0100] 2% of binding material in proportion to the resin amount

[0101] 2% of catalyser in proportion to the resin amount

[0102] 4% of white colouring agent in proportion to the resin amount

[0103] Mixture starts until homogenization and obtaining the second paste which will be transported by a conveyor belt to the feeding mechanism.

[0104] The download of the pastes or masses in the feeding or distributor mechanism is made in a controlled and ordered manner and with the following sequence:

[0105] First, 15 Kg mass 2; second, 10 Kg mass 1; third, 30 Kg mass 2; fourth, 15 Kg mass 1; fifth, 25 Kg mass 2 and finally, 5 Kg mass 1.

[0106] This is, in this case, a thin tile with a total mass of 100 kg will be created being the total distribution of the two different masses in the final tile this following: 70% of mass 2 and 30% of mass 1.

[0107] Then the controlled download of the strati takes place, according to the previous stage, from the feeding mechanism to the mould and then moulding, compressing, hardening, and finishing treatment to the product with the most used techniques in the state of art.