A method and apparatus for producing engineered stone with controllable patterns

Abstract

A controllable patterned artificial stone production apparatus and method are disclosed. The apparatus includes: a mixer; a feeding chamber; a movable mold; a pressing chamber; a cutting device; a polishing and waxing device; and any one or more of a plate, a frame, and a pre-molded patterned material that can be vertically placed in the movable mold and have a preset horizontal cross-sectional shape. The plate is coated with a colorant on its surface, the frame is formed by enclosing the plate and is filled with colorant therebetween, and a lifting device is provided at the upper end of the plate and / or the frame for removing the plate and / or the frame from the movable mold after feeding is completed, leaving the colorant in the artificial stone material, thereby forming a preset pattern in the artificial stone material. The patterned material includes one or more segments, each segment having a similar preset horizontal cross-sectional shape and staggered from each other.

Description

Technical Field

[0001] This invention relates to the field of engineered stone production, specifically to a method and apparatus for producing engineered stone with controllable patterns. Background Technology

[0002] Engineered stone is a type of artificial stone made primarily from calcium carbonate sand, calcium carbonate powder, and resin. It is produced in the form of rectangular blocks (common dimensions: 2.7 meters long, 1.8 meters wide, and 1-1.5 meters high), so its manufacturing process is fundamentally different from that of artificial quartz stone slabs, which are produced in individual pieces.

[0003] The manufacturing process of engineered stone is as follows:

[0004] 1. Using unsaturated resin (with a certain amount of accelerator and curing agent added), sand and powder of different mesh sizes, and pigments of different proportions as raw materials, the color of this mixture is determined by the different types and proportions of pigments. The mixture is thoroughly mixed in one or more mixers, and then fed into a main mixer. The texture and length of the patterns are created by varying the mixing time (sometimes supplemented by powdering, spraying, etc.).

[0005] The engineered stone equipment involves mixing at a high level, with the main mixer (responsible for creating patterns) at the end. The main mixer is connected to the lower discharge chamber and pressing chamber, and can be sealed off and vacuumed. The engineered stone equipment includes: an empty mold waiting area (outside the discharge chamber), a discharge chamber, a main mixer discharge port (top of the discharge chamber), a pressing chamber, and a discharge area for pressed square blocks (outside the pressing chamber). The main mixer, discharge chamber, and pressing chamber are equipped with lights and cameras, projecting images onto a screen for worker convenience.

[0006] 2. Then, under vacuum, the material falls into the mold containing the paper or release agent (with a drop of approximately 2-3 meters). Below the main mixer's discharge port is a discharge frame that is wider at the top and narrower at the bottom, ensuring the material falls completely into the mold. During the discharge process, a movable trolley carrying a mold 2-3 meters long, 1.6-1.8 meters wide, and 1.3-2 meters high reciprocates along its long axis within the discharge chamber, ensuring the material falls evenly and dispersedly within the mold.

[0007] 3. After the material is unloaded, a movable trolley carries the mold to the pressing chamber on the other side. The pressure head descends and high-frequency high-pressure vibration is performed under vacuum to ensure that the square material is dense and without gaps.

[0008] 4. After pressing is complete, release the vacuum, move the trolley carrying the mold outside the pressing room, hoist it to the side, and after the material has reacted and solidified, loosen the mold screws, remove the material from the mold, and clamp it to the side with a special clamp.

[0009] 5. After about a week, use a flipping machine to flip the square material from the intersection of the long axis and the wide axis upwards to the intersection of the long axis and the height axis upwards, and feed it into a gang saw (perpendicular to the height axis) to cut it into boards of the preset thickness, which are called rough boards.

[0010] 6. The rough boards are then polished and waxed to become smooth boards, which can then be packaged and sold.

[0011] The resulting boards, made by dropping tens of tons of material in small, scattered pieces over several minutes, exhibit randomly generated patterns due to the large drop height and dispersed fall. Unlike ceramic tiles or single-piece pressed quartz stone, which can form predetermined, regular patterns, these boards are not produced in this way. Currently, the industry primarily uses color changes to create different types of boards, but the actual shape of the pattern remains largely unchanged.

[0012] Some industry insiders have also made improvements to this method of preparing the cutting material:

[0013] Option 1 involves making the board into a single color and then printing colors on the surface to create various patterns. The advantage is that all colors that can be printed can be applied to the board surface. The disadvantage is that there is only a thin layer on the surface, and the surface pattern will be damaged by slight bumps or processing.

[0014] Option 2 involves adding a belt between the mixing and discharging parts of the mold. The mixing and discharging parts are then placed on the belt, and a roller is added to the belt to press the material. After pressing, the material is sprayed with paste and powder to create patterns. Because the material is compacted, it falls less loosely, and the patterns will be longer, but still relatively short. Moreover, the patterns are still random and cannot form the desired pattern shape.

[0015] Option 3 involves pressing the square material once, then scooping it out of the mold in blocks, and throwing it into a mixer. Through spraying, powdering, or mixing with auxiliary materials, the mixture is then stirred in the main mixer to create patterns in clumps of varying sizes. This method is only suitable for creating specific clump patterns, and the patterns are still randomly generated.

[0016] The colors used in the production of engineered stone refer to titanium dioxide, iron oxide yellow, iron oxide black, iron oxide red, phthalocyanine green, etc. One or more of these are mixed in different proportions according to requirements to create the desired color.

[0017] Pigment paste is a highly fluid slurry made by grinding titanium dioxide, iron oxide pigments, and resin together. It is sprayed onto the surface of the material during application, hence the name "spraying paste." Powder coating involves mixing titanium dioxide, iron oxide pigments, and other pigments to create the desired color, then sprinkling it onto the surface of the material. Because the powder coating is a different color from the material itself, it forms patterns.

[0018] To create patterns on engineered stone, the main and auxiliary materials used are the same: calcium carbonate sand and calcium carbonate powder, but different colors, to achieve the desired pattern effect. There are typically four auxiliary mixers, each mixing materials of a different color. The formation of engineered stone patterns involves using a main material of a certain color, combined with auxiliary materials of different colors, powdering, spraying, etc. (these can be used individually or in combination), and mixing them several times in the main mixer to create different colored patterns.

[0019] Therefore, in summary, currently, engineered stone blocks can only produce short, random patterns, or have a surface coating applied later. They still cannot produce patterns of a predetermined shape throughout the entire block, let alone regular patterns or stable long patterns. Moreover, the production quality and efficiency are relatively low. Summary of the Invention

[0020] In one aspect of the present invention, a controllable patterned artificial stone production apparatus is provided, comprising:

[0021] A mixer, used to mix raw quartz stone into quartz stone material;

[0022] The material discharge chamber is located below the mixer, and a material discharge port is provided between it and the mixer;

[0023] The movable mold can enter the discharge chamber, allowing the mixed quartz material to fall into the movable mold through the discharge port;

[0024] A pressing chamber, located on one side of and connected to the blanking chamber, includes a pressing device for pressing the quartz material in the movable mold into square blocks, wherein the blanking chamber and the pressing chamber can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0025] A cutting device for cutting square blocks taken out from a movable mold into multiple plates;

[0026] Polishing and waxing equipment, used for polishing and waxing boards; and

[0027] Any one or more of a plate, a frame, and a pre-molded patterned material that can be placed vertically in the movable mold and have a preset horizontal cross-sectional shape, wherein the plate is coated with a colorant on its surface, the frame is formed by enclosing the plate and is filled with colorant therebetween, and a lifting device is provided at the upper end of the plate and / or the frame for removing the plate and / or the frame from the movable mold after the material is dropped, leaving the colorant in the slab material, thereby forming a preset pattern in the slab material, wherein the patterned material comprises one or more segments, each segment having a similar preset horizontal cross-sectional shape and being staggered from each other.

[0028] In some embodiments, the lifting device includes:

[0029] Multiple vertical rods fixed to the plate and / or frame;

[0030] A bracket installed on the upper part of the movable mold has multiple holes corresponding to the positions of the multiple rods, and the multiple rods are respectively inserted into the multiple holes;

[0031] Multiple ropes, one end of each rope fixed to the end of a pole;

[0032] A lifting device fixed to the top of the unloading chamber is connected to the other end of the plurality of ropes for lifting the plurality of rods via the plurality of ropes, thereby removing the plate and / or frame out of the movable mold.

[0033] In another aspect of the invention, a controllable patterned artificial stone production apparatus is provided, comprising:

[0034] A mixer is used to mix at least one of the following three materials: raw material of engineered stone, auxiliary materials, color paste, and color powder, into engineered stone material;

[0035] The material discharge chamber is located below the mixer, and a material discharge port is provided between it and the mixer;

[0036] The movable mold can enter the feeding chamber, allowing the mixed quartz stone to fall into the movable mold through the feeding port and move back and forth during the feeding process;

[0037] A pressing chamber, located on one side of and connected to the blanking chamber, includes a pressing device for pressing the quartz material in the movable mold into square blocks, wherein the blanking chamber and the pressing chamber can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0038] A cutting device for cutting square blocks taken out from a movable mold into multiple plates;

[0039] Polishing and waxing equipment, used to polish and wax boards;

[0040] The funnel is located below the discharge port in the discharge chamber. Its lower opening is a long and narrow rectangle, and the long side of the lower opening is perpendicular to the long side of the movable mold, so that the quartz material falling from the discharge port falls into the movable mold through the lower opening of the funnel.

[0041] Multiple ropes, one end of which is fixed to each side of the funnel; and

[0042] The lifting device, fixed at the top of the material discharge chamber and on both sides of the material discharge port, is connected to the other end of the plurality of ropes and is used to lift the funnel through the plurality of ropes, thereby maintaining the distance between the lower opening of the funnel and the material surface in the movable mold during the material discharge process.

[0043] According to an embodiment of the present invention, one end of each of the plurality of ropes is respectively fixed to the upper and lower openings of the funnel, and wherein,

[0044] The lifting device is used to lift the upper and lower openings of the funnel respectively, so that when the movable mold reciprocates to the upper opening of the funnel near one end of the movable mold, the lower opening of the funnel also approaches that end of the movable mold.

[0045] In another aspect of the invention, a controllable patterned artificial stone production apparatus is provided, comprising:

[0046] A mixer, used to mix raw quartz stone into quartz stone material;

[0047] The material discharge chamber is located below the mixer, and a material discharge port is provided between it and the mixer;

[0048] The movable mold can enter the discharge chamber, allowing the mixed quartz material to fall into the movable mold through the discharge port;

[0049] A pressing chamber, located on one side of and connected to the blanking chamber, includes a pressing device for pressing the quartz material in the movable mold into square blocks, wherein the blanking chamber and the pressing chamber can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0050] A cutting device for cutting square blocks taken out from a movable mold into multiple plates;

[0051] Polishing and waxing equipment, used for polishing and waxing boards; and

[0052] Any one or more of the shotcrete device, powder spreading device, and auxiliary mixer, wherein,

[0053] The spraying device is used to spray colored paste onto a layer of engineered stone material that has already fallen into the movable mold;

[0054] The powder-sprinkling device is used to sprinkle color powder onto a layer of engineered stone material that has already fallen into the movable mold;

[0055] The auxiliary mixer is used to discharge auxiliary materials into a movable mold.

[0056] According to an embodiment of the present invention, the artificial stone production apparatus further includes:

[0057] A crusher is used to crush quartz stone from the feeding chamber and drop it into a movable mold.

[0058] In another aspect of the invention, a method for producing engineered stone with controllable patterns is provided, comprising:

[0059] Any one or more of a plate, a frame, and a pre-molded patterned material having a preset horizontal cross-sectional shape are placed vertically in a movable mold, wherein the plate is coated with colorant on its surface, the frame is formed by enclosing the plate and filled with colorant therebetween, and the patterned material comprises one or more segments, each layer of patterned material having a similar preset horizontal cross-sectional shape and being staggered from one another.

[0060] Move the movable mold into the unloading chamber;

[0061] Use a mixer to mix the raw materials of engineered stone into engineered stone material;

[0062] Under vacuum, the quartz stone is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber. During the discharge process, the movable mold moves back and forth from side to side.

[0063] After the blanking is completed, if the plate and / or frame are present, the plate and / or frame are removed from the movable mold, leaving the pigment in the granite, thereby forming a preset pattern in the granite.

[0064] The movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0065] After releasing the vacuum, move the movable mold outside the pressing chamber, and remove the material from the movable mold after it has reacted and solidified.

[0066] After a predetermined time, the square material is cut into multiple plates along a direction perpendicular to its height; and the multiple plates are polished and waxed.

[0067] In one aspect of the present invention, a method for producing engineered stone with controllable patterns is provided, comprising:

[0068] Move the movable mold into the blanking chamber;

[0069] Use a mixer to mix the raw material of artificial stone and at least one of the auxiliary materials, color paste, and color powder to form artificial stone material;

[0070] Under vacuum, the quartz material is fed into a movable mold through a discharge port set between the mixer and the discharge chamber and a funnel set below the discharge port. The lower opening of the funnel is a long and narrow rectangle, and the long side of the lower opening is perpendicular to the long side of the movable mold. During the material feeding process, the movable mold moves back and forth from left to right, while maintaining the distance between the lower opening of the funnel and the material surface.

[0071] After the material is unloaded, the movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0072] After releasing the vacuum, move the movable mold outside the pressing chamber, and remove the material from the movable mold after it has reacted and solidified.

[0073] After a predetermined time, the square block is cut into multiple plates along a direction perpendicular to its width or height; and

[0074] The multiple boards are polished and waxed.

[0075] In another aspect of the invention, a method for producing engineered stone with controllable patterns is provided, comprising:

[0076] Move the movable mold into the blanking chamber;

[0077] Use a mixer to mix the raw materials of engineered stone into engineered stone material;

[0078] Under vacuum, the quartz stone is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber. During the discharge process, the movable mold moves back and forth from side to side.

[0079] After a predetermined quantity and distribution of engineered stone material is dropped into the movable mold, or simultaneously, at least one of the predetermined quantity and distribution of auxiliary materials, color paste, and color powder is sprayed or dropped onto the engineered stone material. The above process is repeated until the material dropping is completed.

[0080] The movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0081] After releasing the vacuum, move the movable mold outside the pressing chamber, and remove the material from the movable mold after it has reacted and solidified.

[0082] After a predetermined time, the square block is cut into multiple plates along a direction perpendicular to its width or height; and

[0083] The multiple boards are polished and waxed.

[0084] In another aspect of the invention, a method for producing engineered stone with controllable patterns is provided, comprising:

[0085] Move the movable mold into the blanking chamber;

[0086] Use a mixer to mix the raw materials of engineered stone into engineered stone material;

[0087] Under vacuum, the quartz stone is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber. During the discharge process, the movable mold moves back and forth from side to side.

[0088] The pattern is formed directly in the engineered stone material in the mold while the material is being cut;

[0089] The movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0090] After releasing the vacuum, move the movable mold outside the pressing chamber, and remove the material from the movable mold after it has reacted and solidified.

[0091] After a predetermined time, the square block is cut into multiple plates along a direction perpendicular to its width or height; and

[0092] The multiple boards are polished and waxed.

[0093] The controllable-pattern artificial stone production apparatus and method according to embodiments of the present invention overcomes the shortcomings of traditional methods, which can only produce random, disordered, short, and superficial patterns. It can produce various preset, full-body patterns, with the shape, thickness, and length of the pattern all preset and unrestricted. It can produce full-body long patterns or mountain-like patterns, and the thickness and density of the pattern can be adjusted. It can obtain distinct, layered, and artificially natural patterns that are impossible to achieve with ordinary methods, such as blocky patterns, and the style, distribution, thickness, and density of the pattern can be easily adjusted. Furthermore, because the pattern has a regularity, patterns with special effects can be obtained by splicing two slabs together. In addition, since the pattern is formed in a mold rather than in a mixer, it saves a significant amount of time compared to the original method, improving production efficiency and quality. Attached Figure Description

[0094] Figure 1 A schematic diagram of a controllable patterned granite production apparatus according to a first embodiment of the present invention is shown;

[0095] Figure 2 The diagram shows a front view, a horizontal cross-sectional view, and a schematic diagram of the pattern of the produced sheet metal, all of which are provided according to a first embodiment of the present invention.

[0096] Figure 3 A method for producing engineered stone with controllable patterns according to a first embodiment of the present invention is shown;

[0097] Figure 4 A schematic diagram of a controllable patterned granite production apparatus according to a second embodiment of the present invention is shown;

[0098] Figure 5 A method for producing engineered stone with controllable patterns according to a second embodiment of the present invention is shown;

[0099] Figure 6 An example of a granite pattern produced using a granite production apparatus and method with controllable patterns according to a second type embodiment of the present invention is shown;

[0100] Figure 7 A schematic diagram of a controllable patterned granite production apparatus according to a third embodiment of the present invention is shown;

[0101] Figure 8 A method for producing engineered stone with controllable patterns according to a third embodiment of the present invention is shown;

[0102] Figure 9 Examples of engineered stone patterns produced using the engineered stone production apparatus and method with controllable patterns according to a third type embodiment of the present invention are shown; and

[0103] Figure 10 A method for producing engineered stone with controllable patterns according to various embodiments of the present invention is shown. Detailed Implementation

[0104] Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Numerous specific details are set forth in the following description to enable those skilled in the art to fully understand the invention. However, it will be apparent to those skilled in the art that implementations of the invention may not include some of these specific details. Furthermore, it should be understood that the invention is not limited to the specific embodiments described. Rather, the invention can be conceived to be practiced with any combination of the following features and elements, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments, and advantages are illustrative only and should not be construed as elements or limitations of the claims unless expressly set forth in the claims.

[0105] The terms used in this specification generally have their common meaning in the art, or their meaning as would be normally understood by a person skilled in the art after reading this specification. The terms "comprising" and "including" in this specification are open-ended, meaning they may include other unmentioned elements in addition to those explicitly mentioned. For example, the apparatus and method of the present invention described in this specification may include other conventional components or steps known to a person skilled in the art, such as those mentioned in the background section of this specification, in addition to the components or steps explicitly described in this specification. The terms "connected," "linked," and similar terms used in this specification generally include mechanical connections, electrical connections, or combinations thereof, and generally include both direct connections and indirect connections or links via other components. Terms indicating orientation in this specification, such as "length," "width," "height," "front," "rear," "left," "right," "up," and "down," refer to the corresponding orientation shown in the drawings or in actual operation. The dimensions, material composition, and content of the components mentioned in this specification are merely examples and not limitations on the invention.

[0106] First type of embodiment

[0107] Now refer to Figure 1 The diagram shows a schematic of a controllable patterned granite production apparatus according to a first embodiment of the present invention.

[0108] like Figure 1 As shown, the controllable patterned artificial stone production apparatus 100 according to a first embodiment of the present invention includes:

[0109] Mixer 110 is used to mix raw quartz stone into quartz stone material;

[0110] The material discharge chamber 120 is located below the mixer 110, and a material discharge port 121 is provided between it and the mixer 110;

[0111] The movable mold 130 can enter the discharge chamber 120, so that the mixed quartz material can fall into the movable mold 130 along the discharge port 121;

[0112] The pressing chamber 140, located on one side of the blanking chamber 120 and connected to the blanking chamber 120, includes a pressing device (not shown) for pressing the quartz material in the movable mold 130 into square material, wherein the blanking chamber 120 and the pressing chamber 140 can be closed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0113] The cutting device 150 is used to cut the square material taken out from the movable mold 130 into multiple plates;

[0114] Polishing and waxing device 160, used for polishing and waxing the board material;

[0115] Any one or more of a plate 131, a frame, and a pre-molded patterned material that can be placed vertically in the movable mold 130 and have a preset horizontal cross-sectional shape, wherein the plate 131 is coated with a colorant on its surface, the frame is formed by enclosing the plate and is filled with colorant therebetween, and a lifting device is provided at the upper end of the plate 131 and / or the frame for removing the plate 131 and / or the frame from the movable mold 130 after the material is dropped, leaving the colorant in the slate, thereby forming a preset pattern in the slate, wherein the patterned material includes one or more segments, each segment having a similar preset horizontal cross-sectional shape and being staggered from each other.

[0116] In some embodiments, the lifting device includes:

[0117] A plurality of vertical rods 134 fixed to the plate 131 and / or the frame;

[0118] A bracket 135 is installed on the upper part of the movable mold 130. The bracket 135 has a plurality of holes corresponding to the positions of the plurality of rods 134, and the plurality of rods 134 are respectively inserted into the plurality of holes.

[0119] Multiple ropes 136, one end of each rope 136 is fixed to the end of a rod 134;

[0120] A lifting motor 137 fixed to the top of the unloading chamber 120 is connected to the other end of the plurality of ropes 136 for lifting the plurality of rods 134 via the plurality of ropes 136, thereby moving the plate 131 and / or the frame out of the movable mold 130.

[0121] The plate 131 can be, for example, an iron plate, and its thickness can be, for example, 3 mm. The number of plates 131 and their preset horizontal cross-sectional shape can be determined according to the desired solid stone pattern.

[0122] The plurality of rods 134 may be, for example, screws, one end of which may be welded to the one or more plates 131, and the other end of which may pass through the bracket. The bracket 135 may be, for example, a support structure built on the upper part of the movable mold 130, used together with the plurality of rods 134 to fix the one or more plates 131, and to suspend them to keep them upright. The plurality of ropes 136 may be, for example, steel wire ropes.

[0123] For example, in actual operation, you can first use 100 parts of unsaturated resin, add 3 parts of hydrogenated castor oil, heat until completely dissolved, then add an equal amount of calcium carbonate sand and calcium carbonate powder, and then add one or more different proportions of titanium dioxide, iron oxide yellow, iron oxide black, iron oxide red, phthalocyanine green, etc., to make a paste for later use.

[0124] Then, after applying cardboard or release agent inside the mold, vertically place multiple 3mm thick iron plates of a pre-designed shape inside the movable mold. The lower end of the iron plates can touch the bottom of the mold, and the upper end can be 30cm lower than the top of the mold. A 3cm diameter, 50cm long screw rod (10cm embedded in the iron plate, 40cm above) can be welded to the upper end of each iron plate at 70cm intervals, leaving 10cm of the screw rod protruding above the mold. Using 10cm channel steel, construct a grid-shaped support system 50cm from each side of the mold (the number of channel steels can be increased depending on the screw rod positions). Drill holes in the channel steel corresponding to the screw rod positions, insert the screw rods into the holes, and then tighten nuts. This suspends the iron plates, ensuring they stand upright.

[0125] For example, a nut is screwed onto the top of each screw, below which is a collar connecting to a steel wire rope. The inner diameter of the collar is larger than that of the screw but smaller than that of the nut. Each steel wire rope is 18 mm in diameter and 8 meters long, with a collar welded to one end and a hoisting motor connected to the other end. The hoisting motor is mounted on the top of the discharge chamber and connected to the screw on the iron plate via the steel wire rope. For example, there can be six hoisting motors, each with a power of 3 kW. The area to the left of the discharge port in the discharge chamber can be raised to 5 meters to accommodate the hoisting motors mounted on top.

[0126] For example, before hoisting the iron plate into the mold, the areas on the iron plate that need coarse patterns are first coated with the paste prepared above, and the areas that need fine patterns are sprayed with color paste (a color paste made by grinding titanium dioxide, iron oxide pigments, etc. with resin) and sprinkled with color powder (color powder made by mixing titanium dioxide, iron oxide pigments, etc. evenly).

[0127] Next, the iron plates are hoisted into the mold and the steel wire rope is connected. Then, the trolley-mounted mold enters the unloading chamber. After the main mixer has mixed the material, under vacuum, the trolley-mounted mold moves back and forth, and the main mixer opens the unloading gate, dropping the material into the mold containing multiple pre-shaped iron plates. After unloading, the trolley-mounted mold moves to below the lifting motor in the unloading chamber. The lifting motor pulls the steel wire rope to raise the iron plates until they are completely detached from the mold. The paste-like substance and colored pigment on the iron plates are retained in the material under the pressure and adhesion of the tens of tons of material. Because the shape of the iron plates is pre-designed, the pattern in the resulting material is also basically the pre-designed pattern.

[0128] For example, the material in the mold is then pulled into the pressing chamber, pressed into shape, vacuumed, and removed from the press. After a week, it is rotated 90 degrees so that the intersection of the long axis and the height axis is facing upwards, and then cut into rough plates perpendicular to the height axis and polished. The iron plates used are then transported out of the unloading chamber by a trolley, reapplied with paste and colorant, and used for the next time.

[0129] In other embodiments, a frame can be used instead of a single sheet of iron. For example, the frame is an open frame formed by two parallel (or non-parallel) iron plates, closed on all four sides. The shape and width of the frame can be set as needed. Further, small slits can be cut from top to bottom at 50-centimeter intervals around the frame (without compromising the strength of the iron plates), allowing air to be extracted during vacuuming. Then, a well-mixed mixture of one or more different colors of the desired color (e.g., a mixture of titanium dioxide, iron oxide, and other pigments prepared on demand, mixed with calcium carbonate sand, calcium carbonate powder, unsaturated resin, accelerator, curing agent, etc.) is poured into the frame, creating very wide patterns. The number and shape of the patterns are still pre-set based on the iron plates and / or the frame. The frame and iron plates can be used individually or in combination. The process is the same as for the iron plates: entering the feeding chamber, feeding through the main mixer, pulling out the iron plates and frame, pressing, etc.

[0130] In some embodiments, special materials, such as optical fibers (transparent strips), can be added and arranged in a predetermined shape, hanging from plastic suspension ropes. These ropes are not connected to steel wire ropes or lifting motors. The plastic suspension ropes suspend above the inside of the mold, and the outer edge of the ropes is secured with plastic ropes and wrapped around anchor rods outside the mold to prevent sagging. After the main mixer pours material into the mold, the trolley directly carries the mold to the pressing chamber to press the material, pressing the plastic ropes and hanging optical fibers together into the material. After the material solidifies and is cut, the sheet with the plastic suspension ropes is discarded; the lower sheet is the one with the predetermined pattern and special material, such as optical fibers forming specially shaped light-transmitting holes.

[0131] In some other embodiments, a silicone mold can be made first, creating two (or more) mold sections with the desired pattern in the middle (viewed from above). The total height of the two mold sections is equal to the height of the material to be pressed. The patterns on the upper and lower sections of the mold are consistent, but they can be staggered in the vertical position (to prevent the press from crushing the already solidified pattern material during pressing; staggering eliminates this risk). Then, a highly fluid slurry is made using calcium carbonate sand, calcium carbonate powder, and resin (this slurry can be monochromatic, multi-colored, or even partially composed of the main material color, thus creating an effect where the main material and the pattern blend). Vacuum... The material is poured into the silicon mold. After the refractory material solidifies and is demolded, the patterned material from the silicon mold is vertically placed into the mold carried by a trolley. The lower end of the lower section is placed against the mold, and the lower and upper ends of the upper section are on the same horizontal plane. Both the lower and upper sections of the patterned material are secured with a rope (the hoist holds one end of the rope, which passes through a round hole drilled 20 cm below the top of the patterned material, and the other end is attached to a hook at the top, with a motor connected to the hook. Once the patterned material can stand stably after being poured, the motor rotates, causing the hook to rotate until it can no longer hold the rope. Then, the rope detaches from the hook and exits through the opening in the patterned material). The patterned material is held by a steel wire rope, hanging in the mold carried by the trolley. The other end of the steel wire rope is attached to a lifting motor at the top of the pouring chamber. After the main mixer has finished pouring the material into the mold, the steel wire rope is pulled out, leaving only the patterned material buried in the mold by the main material. The trolley-mounted mold is then moved to the pressing chamber for pressing.

[0132] Now refer to Figure 2 It shows a front view, a horizontal cross-sectional view, and a schematic diagram of the pattern of the produced sheet metal of the assembled movable mold according to a first embodiment of the present invention. The upper left figure is a front view of the movable mold, the lower left figure is a horizontal cross-sectional view of the movable mold, and the lower right figure is a schematic diagram of the pattern of the produced sheet metal.

[0133] like Figure 2As shown, multiple plates 131 are vertically mounted in a movable mold 130, and multiple rods 134 are fixed to the upper ends of the plates 131. A bracket 135 is mounted on the upper part of the movable mold 130. The bracket 135 is made of grid-shaped channel steel, and multiple holes are provided on the bracket 135 corresponding to the positions of the multiple rods 134. Each rod is inserted into a hole and tightened with a nut, thereby fixing the rods 134 and the plates 130 together. The horizontal cross-section of the multiple plates 131 in the movable mold 130 forms the desired pattern, so that the plates produced by the movable mold 130 will have approximately the same pattern.

[0134] The above description, with reference to the accompanying drawings, outlines a controllable patterned artificial stone production apparatus 100 according to a first-type embodiment of the present invention. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the apparatus may have more, fewer, or different components, and the connections, inclusions, and functional relationships between the components may differ from those described and illustrated. For example, typically a component may include other sub-components in addition to those illustrated and described; multiple components may be combined into a larger component, and so on. For example, in addition to the components described and illustrated above, the apparatus may also include other conventional components used in artificial stone production, as known to those skilled in the art, such as those mentioned in the background section of this specification. For example, the mixer 110 may include a main mixer, or it may include a main mixer and several auxiliary mixers. All these variations are within the spirit and scope of the present invention.

[0135] Now refer to Figure 3 In another aspect of the invention, a method for producing controllable-patterned engineered stone according to a first embodiment of the invention is also provided. The steps of this method correspond to the respective operations of the controllable-patterned engineered stone production apparatus described above according to the first embodiment of the invention. Therefore, some details are omitted in the following description of the method; a more detailed understanding of the method can be obtained by referring to the above description.

[0136] like Figure 3 As shown, the method includes the following steps:

[0137] In step 301, any one or more of a plate, a frame, and a pre-molded patterned material having a preset horizontal cross-sectional shape are placed vertically in a movable mold, wherein the plate is coated with colorant on its surface, the frame is formed by enclosing the plate and filled with colorant therebetween, and the patterned material comprises one or more segments, each segment having a similar preset horizontal cross-sectional shape and being staggered from one another.

[0138] In step 302, the movable mold is moved into the blanking chamber;

[0139] In step 303, the artificial stone raw material is mixed into artificial stone material using a mixer;

[0140] In step 304, under vacuum, the artificial stone material is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber, and the movable mold is moved back and forth from side to side during the dropping process.

[0141] In step 305, after the material is cut off, if the plate and / or frame are present, the plate and / or frame are removed from the movable mold, leaving the colorant in the artificial stone material, thereby forming a preset pattern in the artificial stone material;

[0142] In step 306, the movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0143] In step 307, after releasing the vacuum, the movable mold is moved outside the pressing chamber. After the material has reacted and solidified, the material is removed from the movable mold.

[0144] In step 308, after a predetermined time, the square material is cut into multiple plates along a direction perpendicular to its height.

[0145] In step 309, the plurality of plates are polished and waxed.

[0146] The method for producing controllable patterned engineered stone according to a first embodiment of the present invention has been described above with reference to the accompanying drawings. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the method may have more, fewer, or different steps, and the order, inclusion, and functional relationships between the steps may differ from those described and illustrated. For example, typically a step may be divided into multiple sub-steps; multiple steps may be combined into a larger step, and so on. For example, in addition to the steps described above, the method may also include other conventional process steps in engineered stone production known to those skilled in the art, such as the process steps mentioned in the background section of this specification. All these variations are within the spirit and scope of the present invention.

[0147] The controllable patterned granite production apparatus and method according to the first embodiment of the present invention overcomes the shortcomings of traditional methods, which can only produce random, disordered, short, and superficial patterns. It can produce various preset, full-body patterns, with the shape, thickness, and length of the pattern all preset and unrestricted. Furthermore, due to the regularity of the pattern, patterns with special effects can be obtained by splicing two slabs together. In addition, since the pattern is formed in a mold rather than in a mixer, it saves a significant amount of time compared to the original method, improving production efficiency and quality.

[0148] Second type of embodiment

[0149] Now refer to Figure 4 The diagram shows a schematic of a controllable patterned granite production apparatus according to a second embodiment of the present invention.

[0150] like Figure 4 As shown, the controllable patterned granite production apparatus 400 according to a second embodiment of the present invention includes:

[0151] Mixer 110 is used to mix at least one of the three materials—artificial stone raw material, auxiliary materials, color paste, and color powder—into artificial stone material.

[0152] The material discharge chamber 120 is located below the mixer 110, and a material discharge port 121 is provided between it and the mixer 110;

[0153] The movable mold 130 can enter the discharge chamber 120, so that the mixed quartz material can fall into the movable mold 130 along the discharge port 121;

[0154] The pressing chamber 140, located on one side of the blanking chamber 120 and connected to the blanking chamber 120, includes a pressing device for pressing the quartz material in the movable mold 130 into square material, wherein the blanking chamber 120 and the pressing chamber 140 can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0155] The cutting device 150 is used to cut the square material taken out from the movable mold 130 into multiple plates;

[0156] Polishing and waxing device 160, used for polishing and waxing the board material;

[0157] The funnel 410 is located below the discharge port 121 in the discharge chamber 120. Its lower opening is a long rectangle, and the long side of the lower opening is perpendicular to the long side of the movable mold 130, so that the quartz material falling from the discharge port falls into the movable mold 130 through the lower opening of the funnel.

[0158] Multiple ropes 411, one end of which is fixed to both sides of the funnel 410;

[0159] The lifting device 412, which is fixed to the top of the material discharge chamber 120 and on both sides of the material discharge port 121, is connected to the other end of the plurality of ropes 411 and is used to lift the funnel 410 through the at least two ropes 411, thereby maintaining the distance between the lower opening of the funnel 410 and the material surface during the material discharge process.

[0160] In some embodiments, one end of each of the plurality of ropes 411 is fixed to the upper and lower openings of the funnel 410, respectively, and wherein,

[0161] The lifting device 412 is used to lift the upper and lower openings of the funnel 410 respectively, so that when the movable mold 130 reciprocates to move the upper opening of the funnel 410 close to one end of the movable mold 130, the lower opening of the funnel 410 also closes to that end of the movable mold 130.

[0162] Two lifting devices 412 are installed around the material discharge port 121. The lifting device 412 is, for example, a lifting motor. The lifting motor is connected to multiple ropes 411, for example, steel wire ropes. A funnel 410 is hung below the steel wire ropes. For example, there can be four or more steel wire ropes.

[0163] Figure 4 The upper right part is a top view of the funnel 410. As shown in the figure, the funnel 410 is wider at the top and narrower at the bottom, with both the upper and lower openings being rectangular, for example. The dimensions of the funnel 410 are, for example, 1.7 meters long and 1.2 meters wide at the upper opening, 1.7 meters long and 0.25 meters wide at the lower opening, and 0.6 meters high. For example, four lifting lugs are made at the four corners of the upper opening of the funnel 410, and two lifting lugs are made on the wider side of the lower opening. Each lifting lug can be used to hang a steel wire rope, and the funnel can be raised and lowered by a lifting motor.

[0164] The mixer 410 can mix patterns using existing processes, where the main mixer mixes a main material of one color, the auxiliary mixer mixes auxiliary materials of different colors, or sprays different colored pigments or sprinkles different colored powders (these are three independent methods that can be used individually or in combination). The auxiliary materials are then fed into the main mixer via a belt and mixed for several rotations. Unlike existing processes, more resin is added, for example, 3-5%, to improve the material's fluidity. Then, a vacuum is applied before the material is discharged. Previously, the resin would fall directly into the mold 130 after being constrained by the discharge port 121; now, it falls into the funnel 410. The lifting motor is operated to maintain a distance of 20-30 cm between the bottom of the funnel 410 and the material surface. At this time, the trolley continues to carry the mold 130, reciprocating along its long axis. The long side of the funnel 410 is perpendicular to the long side of the mold in the horizontal direction. As the material surface rises, the funnel 410 also rises, maintaining the distance from the material surface. When the upper opening of the funnel 410 approaches and contacts the wide edge of one side of the mold 130, the lifting motor, which suspends the lower opening of the funnel 410 via a steel wire rope, pulls the lower opening of the funnel 410 to also approach and contact the wide edge of the mold 130 on the same side. When the trolley moves in the other direction, the previously pulling lifting motor lengthens the steel wire rope, while the steel wire rope on the other side gradually tightens. The frequency converter is adjusted to match the speed, so that the upper and lower openings of the funnel 410 on the same side simultaneously approach and contact the wide edge of the mold 130 on the same side. This ensures that the lower opening of the funnel 410 is sufficiently close to both sides of the mold 130, preventing insufficient material from falling at both sides of the mold and thus avoiding the phenomenon of bent end patterns. After the material in the mixer 110 is discharged, and the material in the funnel 410 has almost completely fallen, the funnel 410 is lifted onto the mold 130. The mold 130 is then carried by the trolley to the pressing chamber 140 for pressing and shaping, followed by curing and demolding. After a week, cut the rough board with the long axis and wide axis intersecting upwards, perpendicular to the wide axis; or, as in the existing process, flip it so that the long axis and height axis intersecting upwards, and cut the rough board perpendicular to the height axis. Then, polish it to form a finished board, which will have a continuous long grain or mountain pattern, with the pattern roughly parallel to the long side of the board.

[0165] Unlike existing processes where the quartz stone falls randomly, the quartz stone now falls into the funnel 410 and flows out from the bottom under its own weight. The pattern is forcibly stretched and spread in one direction, resulting in a continuous, parallel pattern. If the material falls unevenly into the funnel, areas with more material will be pressed down, forming a "mountain pattern." Controlling the density of the pattern can produce either dense, parallel patterns or sparse, long patterns. In other words, by mixing main and auxiliary materials of different colors in the mixer (or spraying or sprinkling powder), and then letting them flow down the funnel during the material falling process, the pattern direction is made consistent, thus forming a long and continuous pattern. In this way, by controlling the proportion of main and auxiliary materials, spraying, and sprinkling powder, the amount of pattern can be controlled; by controlling the mixing time of the main mixer, the thickness and distribution density of the pattern can be controlled; and by controlling the coordination of the trolley movement speed and the material falling speed, the material can be prevented from breaking apart, thus achieving the continuity of the pattern and, to a certain extent, controlling the density of the pattern.

[0166] Before use, funnel 410 can be coated with a release agent. After the material remaining on funnel 410 has solidified, it can be knocked off.

[0167] The above description, with reference to the accompanying drawings, outlines a controllable patterned artificial stone production apparatus 400 according to a second embodiment of the present invention. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the apparatus may have more, fewer, or different components, and the connections, inclusions, and functional relationships between the components may differ from those described and illustrated. For example, typically a component may include other sub-components besides those illustrated and described; multiple components may be combined into a larger component, and so on. For example, in addition to the components described and illustrated above, the apparatus may also include other conventional components used in artificial stone production, as known to those skilled in the art, such as those mentioned in the background section of this specification. For example, the mixer 110 may include a main mixer and several auxiliary mixers, and may also include spraying and spreading devices, etc. All these variations are within the spirit and scope of the present invention.

[0168] Now refer to Figure 5 In another aspect of the invention, a method for producing controllable-patterned engineered stone according to a second embodiment of the invention is also provided. The steps of this method correspond to the respective operations of the controllable-patterned engineered stone production apparatus described above according to the second embodiment of the invention. Therefore, some details are omitted in the following description of the method; a more detailed understanding of the method can be obtained by referring to the above description.

[0169] like Figure 5 As shown, the method for producing controllable patterned engineered stone according to a second embodiment of the present invention includes the following steps:

[0170] In step 501, the movable mold is moved into the blanking chamber;

[0171] In step 502, a mixer is used to mix at least one of the following three materials: artificial stone raw material, auxiliary materials, color paste, and color powder, to form artificial stone material;

[0172] In step 503, under vacuum, the artificial stone material is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber and the funnel set below the discharge port. The lower opening of the funnel is a long and narrow rectangle, and the long side of the lower opening is perpendicular to the long side of the movable mold. During the material dropping process, the movable mold moves back and forth from left to right, and the distance between the lower opening of the funnel and the material surface is maintained.

[0173] In step 504, after the material feeding is completed, the movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square material under vacuum.

[0174] In step 505, after releasing the vacuum, the movable mold is moved outside the pressing chamber. After the material has reacted and solidified, the material is removed from the movable mold.

[0175] In step 506, after a predetermined time, the square material is cut into multiple plates along a direction perpendicular to its width or height;

[0176] In step 507, the plurality of plates are polished and waxed.

[0177] The method for producing controllable patterned engineered stone according to a second embodiment of the present invention has been described above with reference to the accompanying drawings. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the method may have more, fewer, or different steps, and the order, inclusion, and functional relationships between the steps may differ from those described and illustrated. For example, typically a step may be divided into multiple sub-steps; multiple steps may be combined into a larger step, and so on. For example, in addition to the steps described above, the method may also include other conventional process steps in engineered stone production known to those skilled in the art, such as the process steps mentioned in the background section of this specification. All these variations are within the spirit and scope of the present invention.

[0178] Figure 6 An example of a granite pattern produced using a granite production apparatus and method with controllable patterns according to a second type embodiment of the present invention is shown.

[0179] The controllable patterned granite production apparatus and method according to the second embodiment of the present invention overcomes the shortcomings of traditional methods, which can only produce random, disordered, short, and superficial patterns, by changing the material feeding method from dropping to flowing out through a funnel. It can produce long, continuous patterns or mountain-like patterns, and the thickness and density of the patterns can be adjusted. Furthermore, because the patterns are regular, patterns with special effects can be obtained by splicing two slabs together. In addition, since the patterns are formed in a mold rather than in a mixer, a significant amount of time is saved compared to the original method, improving production efficiency and quality.

[0180] Third type of embodiment

[0181] Now refer to Figure 7 The diagram shows a schematic of a controllable patterned granite production apparatus according to a third embodiment of the present invention.

[0182] like Figure 7 As shown, the controllable patterned artificial stone production apparatus 700 according to a third embodiment of the present invention includes:

[0183] Mixer 110 is used to mix raw quartz stone into quartz stone material;

[0184] The material discharge chamber 120 is located below the mixer 110, and a material discharge port is provided between it and the mixer.

[0185] The movable mold 130 can enter the discharge chamber 120, so that the mixed quartz material can fall into the movable mold 130 along the discharge port 121;

[0186] The pressing chamber 140, located on one side of the blanking chamber 120 and connected to the blanking chamber 120, includes a pressing device for pressing the quartz material in the movable mold 130 into square material, wherein the blanking chamber 120 and the pressing chamber 140 can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum.

[0187] Cutting device 150 ( Figure 7 (Not shown in the image), used to cut the square material taken out from the movable mold 130 into multiple plates;

[0188] Polishing and waxing equipment 160 ( Figure 7 (Not shown in the image), used for polishing and waxing the sheet material; and

[0189] Any one or more of the shotcrete device 711, the powder spreading device 712, and the auxiliary mixer 713, wherein,

[0190] The spraying device 711 is used to spray colored paste onto a layer of quartz material that has fallen into the movable mold 130;

[0191] The powder-sprinkling device 712 is used to sprinkle color powder on a layer of engineered stone material that has fallen into the movable mold 130;

[0192] The auxiliary mixer 713 is used to discharge auxiliary materials into the movable mold 130.

[0193] In some embodiments, the engineered stone production apparatus 700 further includes a crusher 714, which crushes the engineered stone material from the discharge chamber 110 and allows it to fall into the movable mold 130. The engineered stone material from the mixer 110 varies in size; the crusher 714 can break it into uniform sizes, and then, in conjunction with powdering, spraying, etc., special patterns can be obtained. The crusher 714 can force the engineered stone material through a mesh, breaking it into smaller pieces. Then, by using auxiliary materials or spraying powder to separate the fragments, fine patterns can be formed.

[0194] The spraying device 711, powder spreading device 712, and auxiliary mixer 713 can all be similar to the corresponding devices in the existing process. The difference from the existing process is that the spraying device 711, powder spreading device 712, and auxiliary mixer 713 in the present invention operate in the material dropping chamber 120, spraying, spreading and dropping auxiliary materials directly in the mold 130, instead of operating in the main mixer 110.

[0195] For example, four spray nozzles can be added below the discharge port of the main mixer 110 (two on each side of the discharge port). A pneumatic switch is connected to the back of the spray nozzle, and a 4-point plastic hose is connected to the back of the pneumatic switch. The plastic hose is connected to a conical funnel outside the discharge port. The conical funnel is 50 cm in diameter and 80 cm in height. The bottom is connected to the 4-point hose with a quick connector. The top is sealed, with only a 1-inch switch welded to it to connect to the outside. When the switch is opened, pre-mixed color paste can be poured in through the funnel (the color paste can be made by grinding titanium dioxide, iron oxide pigment, etc. with resin into their respective pastes, and then mixed in different proportions according to the required color). When the switch is closed, the vacuum is isolated.

[0196] The main mixer 110 mixes the material and applies vacuum as usual. During material feeding, the amount and distribution of material falling into the mold 130 are controlled to a suitable level. Then, the feeding port is closed, feeding is paused, the pneumatic switch is activated, and the spray nozzle sprays slurry. The length and distribution of the pattern are determined by controlling the spray range. Then, the spraying is stopped and feeding continues. This process is repeated until feeding is complete.

[0197] Then, the small vehicle-mounted mold 130 presses, releases vacuum, and demolds in the pressing chamber 140. The rough board is cut out with the long axis and wide axis intersecting upwards and perpendicular to the wide axis, or it is rotated 90 degrees and the rough board is cut out with the long axis and height axis upwards and perpendicular to the height axis, and then polished into a finished board.

[0198] The boards produced by this method can have long and continuous "mountain patterns" or discontinuous cracks or clump-like patterns of varying lengths because the material does not move after spraying.

[0199] For example, an auxiliary mixer 713 can be installed next to the main mixer 110, connected above the discharge chamber 120 like the main mixer 110. Alternatively, four additional auxiliary mixers can be connected by belts to the main mixer 110 and the adjacent auxiliary mixer 713. Depending on the desired effect, materials can be discharged into the main mixer 110 and auxiliary mixer 713 first to create the pattern before proceeding to the next stage of discharge. During vacuum discharge, the main mixer 110 discharges to a certain point and closes the discharge gate, while the auxiliary mixer 713 discharges the material. Controlling the flowability of the auxiliary material in the auxiliary mixer 713 controls the coarseness of the pattern, and controlling the material distribution in the auxiliary mixer 713 controls the pattern distribution. The auxiliary material in the auxiliary mixer 713 and the main material in the main mixer 110 are both uniformly mixed materials of calcium carbonate sand, calcium carbonate powder, unsaturated resin, accelerator, and curing agent; the only difference is the color, which is why visible patterns can be formed. Once the auxiliary mixer has discharged a certain amount of material, the discharge gate is closed, and the main mixer switches back to discharging (the main mixer controls the pattern shape). This process is repeated until discharging is complete. Typically, the main material is more abundant and harder, making it easier to form a shape that doesn't deform. Discharging of the main material is paused after a portion has been discharged. The main material can be discharged flat, unevenly distributed (more on one side, less on the other), or undulating like hills. Then, the auxiliary material falls onto the main material. The auxiliary material is softer and, after falling, adheres to the main material, roughly following its shape. The auxiliary material doesn't necessarily need to completely cover the main material; therefore, the pattern is formed where the auxiliary material falls, and the auxiliary material controls the pattern distribution.

[0200] In addition, spraying and / or dusting can also be used. Applying auxiliary materials, spraying, and dusting are independent methods and can be used individually or in combination.

[0201] Spraying or dusting produces finer patterns, while using a secondary mixer to add auxiliary materials can create coarser patterns. Preferably, some of the main material (or a material with a similar color) should be added to the auxiliary material and mixed before being added alternately with the main material to avoid producing monotonous patterns. The density and shape of the patterns vary depending on the distribution of the main and auxiliary materials. Some processes use only one auxiliary material, some include spraying, and some involve mixing several auxiliary materials before adding them.

[0202] The spraying of plaster, sprinkling of powder, and application of auxiliary materials can be performed alternately with the application of main materials. That is, several pieces of main material are piled up in the mold before the application of auxiliary materials or the spraying of plaster and sprinkling of powder. This results in larger patterns. Alternatively, the spraying of plaster, sprinkling of powder, and application of auxiliary materials can be performed simultaneously with the application of main materials. This results in more fragmented patterns.

[0203] The above description, with reference to the accompanying drawings, describes a controllable patterned artificial stone production apparatus 700 according to a third embodiment of the present invention. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the apparatus may have more, fewer, or different components, and the connections, inclusions, and functional relationships between the components may differ from those described and illustrated. For example, typically a component may include other sub-components in addition to the illustrated and described sub-components; multiple components may be combined into a larger component, and so on. For example, in addition to the components described and illustrated above, the apparatus may also include other conventional components used in artificial stone production, as known to those skilled in the art, such as those mentioned in the background section of this specification. For example, the mixer 110 may include a main mixer and several auxiliary mixers, etc. All these variations are within the spirit and scope of the present invention.

[0204] Now refer to Figure 8 In another aspect of the invention, a method for producing controllable-patterned engineered stone according to a third embodiment of the invention is also provided. The steps of this method correspond to the respective operations of the controllable-patterned engineered stone production apparatus 700 described above according to the third embodiment of the invention. Therefore, some details are omitted in the following description of the method; a more detailed understanding of the method can be obtained by referring to the above description.

[0205] like Figure 8 As shown, the method for producing controllable patterned engineered stone according to a third embodiment of the present invention includes the following steps:

[0206] In step 801, the movable mold is moved into the blanking chamber;

[0207] In step 802, the artificial stone raw material is mixed into artificial stone material using a mixer;

[0208] In step 803, under vacuum, the artificial stone material is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber, and the movable mold is moved back and forth from side to side during the discharge process.

[0209] In step 804, after or simultaneously with the predetermined quantity and distribution of engineered stone material falling into the movable mold, at least one of the predetermined quantity and distribution of auxiliary material, color paste, and color powder is sprayed or dropped onto the engineered stone material, and the above process is repeated until the material is dropped.

[0210] In step 805, the movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0211] In step 806, after releasing the vacuum, the movable mold is moved outside the pressing chamber. After the material has reacted and solidified, the material is removed from the movable mold.

[0212] In step 807, after a predetermined time, the square material is cut into multiple plates along a direction perpendicular to its width or height;

[0213] In step 808, the plurality of plates are polished and waxed.

[0214] In some embodiments, the method for producing controllable patterned engineered stone further includes the following step: crushing the engineered stone material using a crusher before it falls into a movable mold.

[0215] The method for producing controllable patterned engineered stone according to a third embodiment of the present invention has been described above with reference to the accompanying drawings. It should be noted that the above description and illustrations are merely examples and not intended to limit the invention. In other embodiments of the invention, the method may have more, fewer, or different steps, and the order, inclusion, and functional relationships between the steps may differ from those described and illustrated. For example, typically a step may be divided into multiple sub-steps; multiple steps may be combined into a larger step, and so on. For example, in addition to the steps described above, the method may also include other conventional process steps in engineered stone production known to those skilled in the art, such as the process steps mentioned in the background section of this specification. All these variations are within the spirit and scope of the present invention.

[0216] Figure 9 Examples of engineered stone patterns produced using an engineered stone production apparatus and method with controllable patterns according to a third type of embodiment of the present invention are shown, wherein the left side illustrates a clump-like pattern formed by dropping auxiliary materials, and the right side illustrates a more clearly defined clump-like pattern formed by spraying and sprinkling powder.

[0217] The controllable patterned granite production apparatus and method according to the third embodiment of the present invention creates patterns by directly dropping auxiliary materials or spraying slurry / powder into a mold. Layered spraying and layering of materials within the mold overcomes the shortcomings of traditional methods, which can only produce random, disordered, short, and superficial patterns. It can obtain distinct, natural-looking patterns that are impossible to achieve with ordinary methods, such as blocky patterns. Previously, only short, fragmented patterns could be produced on granulated boards, but now long patterns are possible, unaffected by the formula. Furthermore, the style, distribution, thickness, and density of the patterns can be easily adjusted. Because the patterns are regular, special effects can be achieved by combining two slabs. In addition, since the patterns are formed in a mold rather than in a mixer, it saves a significant amount of time compared to previous methods, improving production efficiency and quality.

[0218] The above description, with reference to the accompanying drawings, outlines three embodiments of a controllable patterned granite production apparatus and method according to the present invention. As can be seen from the above description, a common technical feature of the various embodiments of the present invention is that the pattern is formed directly in the mold, rather than in a mixer as in the prior art. Therefore, as... Figure 10 As shown, in another aspect of the present invention, a method for producing controllable patterned engineered stone is provided, the method comprising the following steps:

[0219] In step 101, the movable mold is moved into the blanking chamber;

[0220] In step 102, the artificial stone raw material is mixed into artificial stone material using a mixer;

[0221] In step 103, under vacuum, the artificial stone material is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber, and the movable mold is moved back and forth from side to side during the discharge process.

[0222] In step 104, while the material is being dropped, patterns are formed directly in the quartz stone in the mold;

[0223] In step 105, the movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum.

[0224] In step 106, after releasing the vacuum, the movable mold is moved outside the pressing chamber. After the material has reacted and solidified, the material is removed from the movable mold.

[0225] In step 107, after a predetermined time, the square piece is cut into multiple plates along a direction perpendicular to its width or height; and

[0226] In step 108, the plurality of plates are polished and waxed.

[0227] For specific details regarding each step of this method, please refer to the description above, which will not be repeated here.

[0228] While the present invention has been disclosed above through embodiments, it is not limited thereto. Various modifications and alterations made by those skilled in the art without departing from the spirit and scope of the invention should be included within the scope of protection of the invention, which is defined solely by the language of the claims and their equivalents.

Claims

1. A controllable patterned artificial stone production apparatus, comprising: A mixer, used to mix raw quartz stone into quartz stone material; The material discharge chamber is located below the mixer, and a material discharge port is provided between it and the mixer; The movable mold can enter the discharge chamber, allowing the mixed quartz material to fall into the movable mold through the discharge port; A pressing chamber, located on one side of and connected to the blanking chamber, includes a pressing device for pressing the quartz material in the movable mold into square blocks, wherein the blanking chamber and the pressing chamber can be sealed together and evacuated, so that the blanking and pressing operations are carried out in a vacuum. A cutting device for cutting square blocks taken out from a movable mold into multiple plates; Polishing and waxing equipment, used to polish and wax boards; as well as A pre-molded cured pattern material that can be placed vertically in the movable mold and has a preset horizontal cross-sectional shape, the pattern material comprising one or more segments, each segment having a similar preset horizontal cross-sectional shape and staggered from each other.

2. A method for producing engineered stone with controllable patterns, comprising: Pre-molded cured pattern material with a preset horizontal cross-sectional shape is placed vertically in a movable mold. The pattern material includes one or more segments, and each layer of pattern material has a similar preset horizontal cross-sectional shape and is staggered from each other. Move the movable mold into the unloading chamber; Use a mixer to mix the raw materials of engineered stone into engineered stone material; Under vacuum, the quartz stone is dropped into the movable mold through the discharge port set between the mixer and the discharge chamber. During the discharge process, the movable mold moves back and forth from side to side. The movable mold is moved to the pressing chamber, and the quartz material in the movable mold is pressed into square blocks under vacuum. After releasing the vacuum, move the movable mold outside the pressing chamber, and remove the material from the movable mold after it has reacted and solidified. After a predetermined time, the square block is cut into multiple plates perpendicular to its height; and The multiple boards are polished and waxed.

Images