Molding Machine for Synthesizing Stone by Means of Beats of Heavy Hammer, and Processing Technology

Abstract

A molding machine for synthesizing a stone by means of beats of a heavy hammer includes a base, a heavy hammer mounted on the base, and a driving device for driving the heavy hammer. The base is provided with a material-load zone, and the heavy hammer is configured to beat the material-load zone. A processing method for synthesizing a stone by means of beats of a heavy hammer includes the following steps: burdening; material distribution; shaping; and solidification.

Claims

1. A processing method for synthesizing a stone by beating of a heavy hammer, comprising: mixing a mixed aggregate of a synthetic stone, a filler, and an adhesive in a ratio to form a synthetic stone mixture; distributing the synthetic stone mixture evenly onto a conveying belt or into a frame according to a desired thickness; vacuumizing the synthetic stone mixture, and beating the synthetic stone mixture continuously by the heavy hammer, wherein the adhesive in the synthetic stone mixture flows during beating to be distributed uniformly in the synthetic stone mixture and fully filling gaps among particles of aggregates, and squeezing a redundant adhesive out of the synthetic stone mixture to form a dense synthetic stone board; and solidifying the dense synthetic stone board to form a finished product.

2. The method of claim 1, wherein a mass m of the heavy hammer is determined by
m=A×(ρ.sub.aggregate×a%+ρ.sub.adhesive×b%)×V×K where A is a particle amount coefficient of the mixed aggregate of the synthetic stone and is a constant, and A≦1; ρ.sub.aggregate is a particle density of the mixed aggregate of the synthetic stone, a unit of ρ.sub.aggregate is kg/m.sup.3, and a% is a ratio of the mixed aggregate of the synthetic stone; ρ.sub.adhesive is an adhesive density, a unit of ρ.sub.adhesive is kg/m.sup.3, and b% is a ratio of the adhesive; V is a volume of the synthetic stone mixture, and a unit of V is m.sup.3; K is a mass coefficient of the heavy hammer, K is a constant and ranges from 100 to 30.

3. The method of claim 2, wherein the particle amount coefficient A of the mixed aggregate of the synthetic stone is determined by a particle size of the aggregate, and is increased as the particle size of the aggregate is reduced, the particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.8 to 1 when the particle size is less than 100 micrometers; the particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.2 to 0.8 when the particle size ranges from 100 micrometers to 1000 micrometers; and the particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.04 to 0.2 when the particle size is greater than 1000 micrometers.

4. The method of claim 2, wherein the particle amount coefficient A of the mixed aggregate of the synthetic stone is calculated by
A=A.sub.1×R.sub.1%+A.sub.2×R.sub.2%+A.sub.3×R.sub.3% . . . +A.sub.n×R.sub.n% where A.sub.1, A.sub.2, A.sub.3 . . . A.sub.n are coefficients of aggregates with different particle sizes, and R.sub.1, R.sub.2, R.sub.3, . . . R.sub.n are ratios of aggregates with different particle sizes.

5. A molding machine for synthesizing a stone by beating of a heavy hammer, comprising: a base; a heavy hammer mounted on the base; and a driving device for driving the heavy hammer, wherein the base is provided with a material-load zone, and the heavy hammer is configured to beat the material-load zone.

6. The molding machine of claim 5, wherein the heavy hammer comprises: a hammer plate in contact with a synthetic stone mixture in the material-load zone; and a loading plate located on the hammer plate for increasing a weight of the heavy hammer, wherein the loading plate and the hammer plate are connected together.

7. The molding machine of claim 6, wherein a plurality of supports are provided on the hammer plate, and the hammer plate is connected with the loading plate via the supports.

8. The molding machine of claim 6, wherein the loading plate is formed by stacking multilayer loading boards.

9. The molding machine of claim 6, wherein a frame is further provided on the hammer plate, a suspension member is mounted on an edge of the frame, and the suspension member is hooked on the hammer plate.

10. The molding machine of claim 5, wherein the base is provided with a lifting device, and the lifting device is connected with the heavy hammer.

11. The molding machine of claim 5, wherein the driving device is provided on the heavy hammer, and the driving device is composed by a plurality of drivers synchronously connected together.

12. The molding machine of claim 11, wherein the plurality of drivers are synchronously connected together to form a synchronous drive group, and the heavy hammer is provided with at least one synchronous drive group.

13. The molding machine of claim 12, wherein the synchronous drive group is distributed at the same or different layers.

14. The molding machine of claim 6, wherein the driving device is mounted on at least one of the hammer plate and the loading plate.

15. The molding machine of claim 5, wherein the base comprises a monolayer loading board or stacked multilayer loading boards, and gravity of the base is greater than a pulling force instantly generated by the driving device.

16. The molding machine of claim 15, wherein the stacked multilayer loading boards are connected via bolts to form an integral structure, a bottom of a lowermost layer of the stacked multilayer loading boards is in contact with a ground base wholly or largely, the lowermost layer of the stacked multilayer loading boards is extended outwardly to form a connection portion, the connection portion is provided with a plurality of through holes suitable for connection with the ground base, an uppermost layer of the stacked multilayer loading boards is provided with the material-load zone, and the material-load zone is provided with a protection layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 is a front view of the present disclosure;

[0034] FIG. 2 is a top view of the present disclosure without a loading plate;

[0035] FIG. 3 is a perspective view of the present disclosure;

[0036] FIG. 4 is a cross sectional view of a first embodiment of the present disclosure;

[0037] FIG. 5 is a cross sectional view of a second embodiment of the present disclosure;

[0038] FIG. 6 is a cross sectional view of a third embodiment of the present disclosure;

[0039] FIG. 7 is a cross sectional view of a fourth embodiment of the present disclosure.

DETAILED DESCRIPTION

[0040] With reference to FIGS. 1-4, in embodiments of the present disclosure, a molding machine for synthesizing a stone by means of beating of a heavy hammer is provided and comprises a base 1, a heavy hammer 10 mounted on the base 1 and a driving device 4 for driving the heavy hammer 10. The base 1 is provided with a material-load zone, and the heavy hammer 10 is configured to beat the material-load zone. The heavy hammer provided by the present disclosure has sufficient weight and directly beats the synthetic stone mixture in the material-load zone to press the synthetic stone mixture. In terms of a manner for molding the synthetic stone, the “means of beating of a heavy hammer” provided by the present disclosure is totally different from a “press & vibration” manner in the prior art. The present disclosure overcomes a virtual pressure problem existing in the prior art. The adhesive in the synthetic stone mixture flows by means of “beating”, thus being distributed uniformly in the synthetic stone mixture and fully filling gaps among particles of the aggregates, and a redundant adhesive can be squeezed out of the synthetic stone mixture, thus press properly the synthetic stone mixture.

[0041] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the heavy hammer 10 comprises a hammer plate 2 in contact with a synthetic stone mixture in the material-load zone and a loading plate 3 located on the hammer plate 2 for increasing weight, and the loading plate 3 and the hammer plate 2 are connected together. The present disclosure is provided with a combined weight structure of the hammer plate 2 and the loading plate 3 to form an independent heavy hammer beating unit without pressure system. This structure may provide a beating force required by synthetic stone molding. The present disclosure may not only omit the pressure system as well as solve the virtual pressure problem, but also shorten a molding time of the synthetic stone. The heavy hammer beating unit formed by the hammer plate 2 and the loading plate 3 and being without pressure system is different from the molding machine for synthesizing a stone with pressure system generally used in the prior art.

[0042] The hammer plate 2 and the loading plate 3 in the present disclosure may be separated from each other or an integral structure. The hammer plate 2 is mainly configured to press the synthetic stone mixture, and the loading plate 3 is configured to provide a weight so as to increase a beating force. A structure of the loading plate 3 is much greater than that of the hammer plate 2, thus satisfying the beating force required by pressing.

[0043] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, a plurality of supports 21 are provided on the hammer plate 2, and the hammer plate 2 is connected with the loading plate 3 via the supports 21. Each of the supports 21 is formed by an upper transverse plate, a lower transverse plate and a plurality of vertical plates for connecting the upper transverse plate and the lower transverse plate. In this embodiment, the number of the supports 21 is 4, and the four supports 21 are located at four corners of the hammer plate 2 respectively, thus supporting the loading plate 3 to form a cavity structure. The supports 21 in the present disclosure have a relatively higher supporting force, which may satisfy a support requirement.

[0044] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the loading plate 3 is formed by stacking multilayer loading boards 31. The multilayer loading boards 31 are connected together via a bolt. In the embodiments of the present disclosure, the loading board may use a solid steel sheet or a board made of other heavy material. In the embodiments of the present disclosure, the pressures are all provided by the loading plate 3, and thus the loading plate 3 has a large weight. The materials and structures mentioned above can provide enough beating force. By adjusting the number of the loading board 31, a weight of the heavy hammer is adjusted. Certainly, the loading board 31 in the present disclosure may also be a monolayer structure.

[0045] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, a frame 22 is further provided on the hammer plate 2, a suspension member 23 is mounted on an edge of the frame 22 and hooked on the hammer plate 2. The frame 22 is configured to define a shape of the synthetic stone mixture. The hammer plate 2 presses the synthetic stone mixture within the frame 22, and the suspension member 23 is configured to connect the frame 22 and the hammer plate 2. When the hammer plate 2 is lifted, the frame 22 is driven to be lifted.

[0046] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the base 1 is provided with a lifting device 11, and the lifting device 11 is connected with the heavy hammer 10. In this embodiment, the lifting device 11 is connected with the loading plate 3, the lifting device 11 is a hydraulic cylinder, a portion of the loading plate 3 is extended outwardly to form a support ear, and the lifting device 11 is connected with the support ear. In this way, it is convenient for the lifting device 11 to lift the loading plate 3 and the hammer plate 2.

[0047] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the driving device 4 is provided on the heavy hammer 10, and the driving device 4 comprises a plurality of drivers synchronously connected together. The plurality of drivers are synchronously connected together to form a synchronous drive group, and the heavy hammer 10 is provided with at least one synchronous drive group. The driving device 4 can generate a force greater than a gravity of the heavy hammer, and thus the driving device 4 may lift the heavy hammer and drive the heavy hammer 10 in a certain speed to beat the synthetic stone mixture. The driving device 4 in the present disclosure may also be other structure form, for example, a driving device disposed out of the heavy hammer, which may drive the heavy hammer performing an up-down reciprocating motion to form beating. In the embodiment of the present disclosure, the driving device 4 is synchronized to be a plurality of groups, which may provide sufficient lifting force for driving the heavy hammer.

[0048] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, there is a cavity formed between the hammer plate 2 and the loading plate 3, so that the driving device 4 is mounted in the cavity. The cavity provides a mounting space for the driving device 4. Certainly, the cavity may also be formed by the multilayer loading boards.

[0049] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the synchronous drive group is distributed at same or different layers. The synchronous drive group is mounted on the hammer plate and/or on the loading plate. FIG. 4 shows a same layer arrangement of the first embodiment. There are four groups, in which each one of the two middle groups comprises four drivers connected in series respectively, while each one of the two side groups comprises two drivers connected in series respectively. Certainly, in the embodiments of the present disclosure, the driving device may also be hierarchically arranged. For example, FIG. 5 shows a second embodiment, in which two groups of driving device 4 are disposed in a direction of up and down in the cavity. FIG. 6 shows a third embodiment, in which a driving device 4 is disposed on a top of the loading plate 3. Certainly, the driving device 4 may also be disposed on the hammer plate 2 and the loading plate 3 simultaneously. In the embodiments of the present disclosure, the driving device may be one or more of a vibration motor, a hydraulic driver, an air driver and an electromagnetic driver.

[0050] FIG. 7 shows a fourth embodiment of the present disclosure. A primary difference between the fourth embodiment and other embodiments described above is that, a width or a length of the loading plate 3 is greater than that of the hammer plate, and a portion of the loading plate 3 extends out of the hammer plate 2 to form an additional weight. Such structure may reduce a height of the loading plate 3 with remaining sufficient weight of the loading plate 3 and facilitate an arrangement of the apparatus.

[0051] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the base 1 is a monolayer loading board 15 or stacked multilayer loading boards 15, and a gravity of the base 1 is greater than a pulling force instantly generated by the driving device 4. In the embodiments of the present disclosure, the base is a plate structure, which has a more stable contact with the ground base and thus it is not easy to displace. Since a volume and a weight of the base 1 are relatively greater, a relatively greater gravity can be generated. This gravity is greater than the pulling force instantly generated by the driving device 4, such that the base 1 cannot be pulled by the driving device 4, and thus the base 1 may not vibrate. In this way, a problem that a vibration of the base weakens a beating force of the synthetic stone mixture is solved. Meanwhile, the majority of the beating force generated by the driving device 4 acts on the synthetic stone mixture, thus enhancing the molding effect and saving energy. For example, in this embodiment, there are 12 drivers, which may generate a pulling force of 100 tons, while the base 1 is 110 tons in weight, such that the driving device 4 cannot drive the base 1 to vibrate.

[0052] With reference to FIGS. 1-4, in the above embodiments of the present disclosure, the multilayer loading boards 15 are connected via bolts 16 to form an integral structure. In the embodiments of the present disclosure, the base 1 is an integral structure, and thus the driving device 4 cannot drive a portion of the base 1 to vibrate. A bottom of a lowermost layer of the loading boards is in contact with the ground base wholly or largely. A bottom of the base 1 is in contact with the ground base as much as possible, such that the base 1 is more stable and it is not easy to displace. The base 1 is stable, such that the beating force of the heavy hammer 10 may act on the synthetic tone mixture as much as possible. The lowermost layer of the loading boards 15 is extended outwardly to form a connection portion 151, the connection portion 151 is provided with a plurality of through holes 17 suitable for connection with the ground base. In the embodiments of the present disclosure, the ground base uses a concrete placement structure, a vibration isolating zone is disposed on an edge of the ground base, a connection member is disposed on the ground base, and the base 1 and the ground base are connected together via bolts. In this way, further the base is not easy to displace. An uppermost layer of the loading board 15 is provided with the material-load zone, and the material-load zone is provided with a protection layer 18. The protection layer 18 provides protective action to a material-load belt that passes through the material-load zone.

[0053] According to embodiments of the present disclosure, a processing method for synthesizing a stone by means of beating of a heavy hammer is provided, comprising steps of: [0054] A. burdening, including mixing a mixed aggregate of the synthetic stone, a filler and an adhesive in a ratio to form a synthetic stone mixture; [0055] B. material distributing, including distributing the synthetic stone mixture evenly onto a conveying belt or into a frame according to a desired thickness; [0056] C. shaping, including vacuumizing the synthetic stone mixture, then beating the synthetic stone mixture continuously by the heavy hammer, wherein the adhesive in the synthetic stone mixture flows during beating, thus being distributed uniformly in the synthetic stone mixture and fully filling gaps among particles of the aggregates, and a redundant adhesive is squeezed out of the synthetic stone mixture to form a dense synthetic stone board; [0057] D. solidifying, including solidifying the molded synthetic stone board to form a finished product.

[0058] In the above embodiments of the present disclosure, a mass m of the heavy hammer is determined by a formula,

m=A×(ρ.sub.aggregate×a%+ρ.sub.adhesive×b%)×V×K

[0059] where A is a particle amount coefficient of the mixed aggregate of the synthetic stone, A is a constant, and A≦1;

[0060] ρ.sub.aggregate is a particle density of the mixed aggregate of the synthetic stone, a unit of ρ.sub.aggregate is kg/m.sup.3, and a% is a ratio of the mixed aggregate of the synthetic stone;

[0061] ρ.sub.adhesive is an adhesive density, a unit of ρ.sub.adhesive is kg/m.sup.3, and b% is a ratio of the adhesive;

[0062] V is a volume of the synthetic stone mixture, and a unit of V is m.sup.3;

[0063] K is a mass coefficient of the heavy hammer, K is a constant and ranges from 100 to 3000. Preferably, K ranges from 800 to 3000, and may take a value of 1500 or 2000. K is determined by a variety of the matter according to experience, and it usually takes a value of 1500.

[0064] The particle amount coefficient of the mixed aggregate of the synthetic stone is determined by a particle size of the aggregate, and is increased as the particle size of the aggregate is reduced. The particle amount coefficient A of the mixed aggregate of the synthetic stone is determined by a particle size of the aggregate, and is increased as the particle size of the aggregate is reduced. The particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.8 to 1 if the particle size is less than 100 micrometers; the particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.2 to 0.8 if the particle size ranges from 100 micrometers to 1000 micrometers; and the particle amount coefficient A of the mixed aggregate of the synthetic stone is 0.04 to 0.2 if the particle size is greater than 1000 micrometers.

[0065] In the embodiments of the present disclosure, the particle amount coefficient of the mixed aggregate of the synthetic stone is used for reflecting an aggregate amount per unit volume. If the amount is large, it means that a displacement force required by the aggregate is great, and the heavy hammer beating force is required to be great. The particle amount coefficient of the mixed aggregate of the synthetic stone is determined by an overall particle size according to experience.

[0066] The particle amount coefficient A of the mixed aggregate of the synthetic stone is calculated by

A=A.sub.1×R.sub.1%+A.sub.2×R.sub.2%+A.sub.3×R.sub.3% . . . +A.sub.n×R.sub.n%

[0067] where A.sub.1, A.sub.2, A.sub.3 . . . A.sub.n are coefficients of aggregates with different particle sizes, and R.sub.1, R.sub.2, R.sub.3, . . . R.sub.n are ratios of aggregates with different particle sizes.

[0068] In this embodiment, quartz is taken for example. A density of quartz is ρ.sub.aggregate=2600 kg/cm.sup.3. A generally used particle size of the matter comprises: 13 μm, 18 μm, 23 μm, 38 μm, 45 μm, 58 μm, 109 μm, 212 μm, 380 μm, 830 μm, 1700 μm, 3350 μm, 4750 μm and 8000 μm. According to experience, it is firstly determined that the coefficient of aggregate with minimum particle size of 13 μm is 1, and the coefficients of aggregate with other particle sizes are 0.99, 0.98, 0.95, 0.91, 0.89, 0.79, 0.68, 0.58, 0.30, 0.15, 0.12, 0.08, 0.05, respectively.

[0069] A synthetic stone quartz board with a length of 1 m, a width of 1 m and a height of 0.01 m is pressed, in which the amount of aggregate is a%=90%, quartz with particle size of 38 μm is 30%, quartz with particle size of 109 μm is 20%, quartz with particle size of 212 μm is 20%, quartz with particle size of 380 μm is 21%, the density of the adhesive is ρ.sub.adhesive=1130 kg/m.sup.3, and the ratio of the adhesive is b%=9%.

Then, A=0.95×30%+0.79×20%+0.68×20%+0.58×21%=0.285+0.158+0.136+0.1218=0.7008, and

the mass of the heavy hammer is m=0.7008×(2600×91%+1130×9%)×0.01×1500=25940.46 kg.

[0070] If the heavy hammer is configured according to the weight above, it may satisfy a board molding requirement for manufacturing a board. According to embodiments of the present disclosure, when selecting an experience value, in principle the mass of the heavy hammer for pressing a synthetic stone with a thickness of 1cm, a width of 1 m and a length of 1 m is 1 ton to 35 tons. A particular value is determined by elements including a shape of the board, a thickness of the board, a variety of the matter, a particle size of the matter, etc. Technical features of the heavy hammer determined in the processing method embodiments of the present disclosure are also suitable for the molding machine embodiments.