Artificial stone manufacturing equipment

Abstract

The present invention relates to an artificial stone manufacturing equipment that comprises: a base (1) which has a sturdy structure to support and install other components of the equipment; a fixed frame (2); a mold holder (3); a mold (4); a movable frame (5) installed on the fixed frame (2); a press plate (6); vibrating mechanism (7) mounted on the top side of the press plate (6) to transmit the vibration to press plate (6); a hanging rack (8) used for hanging the vibrating mechanism (7); an airtight plate (9) which has one end installed airtightly to the press plate (6), the other end installed airtightly to a press frame (10); a spacer (11) mounted to the underside of the press frame (10); when the spacer (11) presses up the mold holder (3), a mold storage chamber (12) is created between the mold holder (3), the press plate (6), the airtight plate (9), the press frame (10), and the spacer (11).

Description

ARTIFICIAL STONE MANUFACTURING EQUIPMENTTechnical Field

[0001] The present invention relates to an artificial stone manufacturing equipment, in particular to an artificial stone manufacturing equipment that can manufacture artificial stones of various shapes, such as flat, curved, wavy or other shapes.Background Art

[0002] Artificial stone is getting more and more applications in the field of civil construction, industrial construction and other fields. Currently, the common method used to produce artificial stone is the vacuum vibration press method. According to this method, the vibration is transmitted to a mold, making aggregate compositions easily bind together, and vacuuming also promotes the binding process of the aggregate compositions, removes entrained air in the mixture from the aggregates, improves durability and limits defects in the resulting stone slabs. The current types of artificial stone manufacturing equipment using the vacuum vibration press method use an eccentric vibrator as the vibrating mechanism. The eccentric vibrator is mounted directly on the top of the vacuum vibration press machine. For example, Chinese patent application publication No. CN202622962U relates to an artificial stone manufacturing equipment using the vacuum vibration press method, in which the equipment includes an airtight chamber made between a press table and a rack through a spacer located between the press table and the rack. The eccentric vibrator is arranged directly on the press table. However, with the structure of the artificial stone manufacturing equipment and how the vibrator is located directly on the press table, when operating, the vibrator will not only transmit vibration to the mold and the aggregates but also to the other components of the equipment. Therefore, it is necessary to use a vibrator with a large capacity to make enough vibration for the whole equipment, however large vibrations reduce other components’ longevity.

[0003] In addition, the inventor realized that the artificial stone manufacturing equipment nowadays can only manufacture flat-shaped stones, there is not any equipment currently with the capability of producing complex-shaped stones such as curved or wavy shapes. Meanwhile, the demand for more complex- shaped stones used for construction or decoration of the building surfaces is a very practical need.Summary of Invention

[0004] To overcome the above problems of the known technical solutions, the present invention provides an artificial stone manufacturing equipment that comprises: a base which has a sturdy structure to support and install other components of the equipment; a fixed frame including pillars permanently installed with the base and beam bars permanently installed with the pillars; a mold holder having a shape appropriate to the shape of stone slab to be manufactured; a mold used to contain aggregates and shape the stone slabs; a movable frame that is installed on the fixed frame and can move up and down along the pillars; a press plate having a shape corresponding to the shape of the mold holder to press the mold tightly on the mold holder; a vibrating mechanism mounted on the top side of the press plate to transmit the vibration to the press plate; a hanging rack used for hanging the vibrating mechanism which is permanently installed with the movable frame; an airtight plate that has one end installed airtightly to the press plate, and the other end installed airtightly to a press frame; wherein the airtight plate is made of soft materials so that the vibration from the vibrating mechanism can be concentrated on the press plate and limit its transmission to other components of the equipment; a spacer that is made of elastic materials mounted to the underside of the press frame; when vibrating and pressing the aggregates, the movable frame moves down, making the spacer press up the top side of the mold holder, which creates a mold storage chamber between the mold holder, the press plate, the airtight plate, the press frame, and the spacer.

[0005] Preferably, if the mold storage chamber is connected to a vacuum machine via suction pipes.

[0006] Preferably, if the hanging rack has a structure consisting of three segments and the incline angle between these segments can be adjusted in accordance with the shape of the stone to be manufactured.

[0007] To manufacture curved-shaped stone, the mold holder and the press plate are curved respectively, and the two segments on both sides of the hanging rack are installed in a way that is tilted downwards such that the vibrating mechanism can be pressed against the upper surface of the press plate.

[0008] Preferably, if the equipment has a plurality of vibrating mechanisms, and the vibrating mechanisms are axial vibrating mechanisms that operate alternatively to transmit the vibration to each portion of the press plate.

[0009] The present invention also provides an artificial stone manufacturing equipment that comprises: a base which has a sturdy structure to support and install other components of the equipment; a fixed frame including pillars permanently installed with the base and beam bars permanently installed with the pillars; a mold holder having a shape appropriate to the shape of stone slab to be manufactured; a mold used to contain aggregates and shape the stone slabs; a movable frame that is installed on the fixed frame and can move up and down along the pillars; a press plate having a shape corresponding to the shape of the mold holder to press the mold tightly on the mold holder; a vibrating mechanism mounted on the top side of the press plate to transmit the vibration to the press plate; a hanging rack used for hanging the vibrating mechanism which is permanently installed with the movable frame; wherein the hanging rack has a structureconsisting of three segments and the incline angle between these segments can be adjusted in accordance with the shape of the stone to be manufactured.

[0010] Preferably, if the two segments on both sides of the hanging rack are installed in a way that is tilted downwards to manufacture curved-shaped stone.

[0011] Preferably, if the equipment has a plurality of vibrating mechanisms, and the vibrating mechanisms are axial vibrating mechanisms that operate alternatively to transmit the vibration to each portion of the press plate.Brief Description of the Drawings

[0012] Figure 1 is a side view showing an artificial stone manufacturing equipment according to an embodiment of the present invention in a state when the press plate 6 is raised;

[0013] Figure 2 is an enlarged view of part A in Figure 1 ;

[0014] Figure 3 is a side view showing an artificial stone manufacturing equipment according to an embodiment of the present invention in a state when the press plate 6 is lowered;

[0015] Figure 4 is a side view showing an artificial stone manufacturing equipment according to an embodiment of the present invention in a state when two segments at both sides 8a, 8c of the hanging rack 8 are modified to manufacture curved-shaped stone with a smaller curvature;

[0016] Figure 5 is a side view showing an artificial stone manufacturing equipment according to an embodiment of the present invention in a state when all three segments 8a, 8b, and 8c of the hanging rack 8 are modified into a straight line to produce flatshaped stone;

[0017] Figure 6 is a schematic perspective view of an artificial stone manufacturing equipment according to an embodiment.Description Of Embodiments

[0018] As shown in Figure 1 and Figure 3, the artificial stone manufacturing equipment according to an embodiment of the present invention includes base 1 which has a sturdy structure to support and install other components of the equipment. Fixed frame 2includes pillars 21 permanently installed with base 1 and beam bars 22 permanently installed with pillars 21.

[0019] Mold holder 3 has a shape appropriate to the shape of stone slab to be manufactured. For instance, when manufacturing flat-shaped stone, the mold holder has a flat shape, when manufacturing curved-shaped stone, the mold holder has a corresponding curved shape. The mold holder needs to have a certain strength and can be made of steel or another kind of alloy to ensure it can hold the pressure during manufacturing the stones.

[0020] Mold 4 is used to contain aggregates and shape the stone slabs. When manufacturing curved-shaped stone, the aggregates are spread evenly in the mold 4, and covered before being put on the mold holder to prevent the aggregates from spilling. The mold can be made of elastic materials, such as rubber or fabric reinfored rubber (rubber is imbedded with fabric) so that it can be bent when manufacturing curvedshaped stone.

[0021] Movable frame 5 is installed on the fixed frame 2 and can move up and down along the pillars 21 using electric motors, hydraulic cylinders or other adaptable means (not shown in the drawing).

[0022] Press plate 6 has a shape corresponding to the shape of the mold holder 3 to press the mold 4 tightly on the mold holder 3. Specifically, when the mold holder 3 has a curved shape, the press plate 6 has a coresponding curved shape. When the mold holder 3 has a flat shape, the press plate 6 has a flat shape as well.

[0023] Vibrating mechanism 7 is mounted on the top side of the press plate 6 to transmit the vibration to the press plate 6, from then transmitting the vibration to the aggregates contained inside the mold to increase the tightness and the adhesion between the aggregate compositions. For optimal operation, the vibrating mechanism 7 can be an axial vibrating mechanism operated by electricity, hydraulics, compressed air or otherwise. In addition, in case of using a plurality of vibrating mechanisms 7, the mechanisms may operate independently or alternately to increase the vibration efficiency and minimize the impact on other components of the artificial stone manufacturing equipment.

[0024] Hanging rack 8 is used for hanging or installing the vibrating mechanism 7 which is permanently installed with the movable frame 5. Thus, when the movable frame 5 moves up and down during operation, the whole hanging rack 8, the vibrating mechanism 7, and the press plate 6 move as well. According to an embodiment of the present invention, the hanging rack 8 has a structure consisting of three segments 8a, 8b, and 8c, and the incline angle between the segments 8a, 8b, and 8c can be adjusted in accordance with the shape of the stone to be manufactured as requirements. For instance, when manufacturing curved stone slabs according to the embodiment shown in Figure 1 and Figure 3, the two segments on both sides 8a, 8c of the hanging rack 8 are installed at an angle downwards consistent with the curvature of the stone slab.

[0025] When manufacturing stones with a lower curvature as shown in the embodiment in Figure 4, the incline angle of the two segments on both sides 8a, 8c of the hanging rack 8 are adjusted to be smaller. When manufacturing flat stones as shown in the embodiment in Figure 5, the segments 8a, 8b, and 8c of the hanging rack 8 are installed aligned straight. Additionally, when manufacturing stone slabs with other shapes, it is only necessary to replace the mold holder 3, the press plate 6, and a part of the movable frame 5 connected to an airtight plate 9. It can be seen that the structure of the hanging rack 8 consisting of three segments 8a, 8b, and 8c helps the equipment according to the present invention to manufacture artificial stone slabs with different shapes. Furthermore, although the drawings only show the hanging rack 8 consisting of three segments 8a, 8b, and 8c, it can be understood that the hanging rack 8 can have more than three segments while still having equivalent functions and uses, so it should be understood that the hanging rack with more than three segments is still within the scope of the present invention.

[0026] In the process of manufacturing artificial stone, to enhance the quality of the artificial stone, the tightness and the adhesion of the aggregate compositions need to be increased. Therefore, besides transmitting the vibration to the aggregates in the mold 4, a low-pressure environment needs to be created inside the mold by using vacuum machine. With the types of equipment according to the known technical solutions with wide mold storage chamber, it is usually necessary to use vacuum machine with a large capacity, long suction time and much electricity consumption. To ensure the tightness between the press plate 6 and the mold holder 3 and also shrink the mold storagechamber 12, the present invention provides the use of the airtight plate 9 which has one end installed airtightly to the press plate 6, the other end installed airtightly to a press frame 10. Wherein the airtight plate 9 is made of soft materials, like leather or rubber, fabric reinfored rubber, polymer material, such that the vibration from the vibrating mechanism 7 can be concentrated on the press plate 6 and limit its transmission to the press frame 10 and the lower part of the movable frame 5, thereby increasing the vibration efficiency of the vibrating mechanism. A spacer 11 made of elastic materials, such as rubber or polymer, is mounted to the underside of the press frame 10. Both the spacer 11 and the press frame 10 surrounds the mold 4 to ensure the airtightness of the mold storage chamber 12. As shown in Figure 2, the spacer 11 can be arranged in the groove on the underside of the press frame 10 to avoid shifting during operation.

[0027] As shown in Figure 3, when vibrating and pressing the aggregates, the movable frame 5 moves downward, causing the spacer 11 to press against the upper surface of the mold holder 3, thereby creating the mold storage chamber 12 between the mold holder 3, the press plate 6, the airtight plate 9, the press frame 10, and the spacer 11.

[0028] As shown in Figure 6, the mold storage chamber 12 is connected to the vacuum machine via suction pipes 13. Following the present invention’s structure, the volume of the mold storage chamber 12 is reduced to a minimum, also the airtightness of the mold storage chamber 12 is ensured. As a result, the vacuuming process can take place quickly with only a small capacity vacuum machine.

[0029] It should be understood that the embodiments described above and shown in the drawings are intended only to illustrate the invention. People with average knowledge in the field can alter the equipment in different ways, for instance changing the dimensions of the components, replacing one or more components of the equipment with other components of equivalent structure or function. However, it should be understood that those modifications still have the same nature and are within the scope of the present invention as defined in the accompanying claims.

Claims

CLAIMS1. An artificial stone manufacturing equipment that comprises: a base (1) which has a sturdy structure to support and install other components of the equipment; a fixed frame (2) including pillars (21) permanently installed with the base (1) and beam bars (22) permanently installed with the pillars (21); a mold holder (3) having a shape appropriate to the shape of stone slab to be manufactured; a mold (4) used to contain aggregates and shape the stone slabs; a movable frame (5) that is installed on the fixed frame (2) and can move up and down along the pillars (21); a press plate (6) having a shape corresponding to the shape of the mold holder (3) to press the mold (4) tightly on the mold holder (3); a vibrating mechanism (7) mounted on the top side of the press plate (6) to transmit the vibration to the press plate (6); a hanging rack (8) used for hanging the vibrating mechanism (7) which is permanently installed with the movable frame (5); an airtight plate (9) that has one end installed airtightly to the press plate (6), and the other end installed airtightly to a press frame (10); wherein the airtight plate (9) is made of soft materials so that the vibration from the vibrating mechanism (7) can be concentrated on the press plate (6) and limit its transmission to other components of the equipment; a spacer (11) that is made of elastic materials mounted to the underside of the press frame (10); when vibrating and pressing the aggregates, the movable frame (5) moves down, making the spacer (11) press up the top side of the mold holder (3), which creates a mold storage chamber (12) between the mold holder (3), the press plate (6), the airtight plate (9), the press frame (10), and the spacer (11).

2. The equipment according to claim 1, wherein the mold storage chamber (12) is connected to a vacuum machine via suction pipes (13).

3. The equipment according to claim 1 or 2, wherein the hanging rack (8) has a structure consisting of three segments (8a, 8b, and 8c), and the incline angle between these segments (8a, 8b, and 8c) can be adjusted in accordance with the shape of the stone to be manufactured.

4. The equipment according to any one of claims 1 to 3, wherein to manufacture curvedshaped stone, the mold holder (3) and the press plate (6) are curved respectively, and the two segments on both sides (8a, 8c) of the hanging rack (8) are installed in a way that is tilted downwards such that the vibrating mechanism (7) can be pressed against the upper surface of the press plate (6).

5. The equipment according to any one of claims 1 to 4, wherein the equipment has a plurality of vibrating mechanisms (7), and the vibrating mechanisms (7) are axial vibrating mechanisms that operate alternatively to transmit the vibration to each portion of the press plate (6).

6. An artificial stone manufacturing equipment that comprises: a base (1) which has a sturdy structure to support and install other components of the equipment; a fixed frame (2) including pillars (21) permanently installed with the base (1) and beam bars (22) permanently installed with the pillars (21); a mold holder (3) having a shape appropriate to the shape of stone slab to be manufactured; a mold (4) used to contain aggregates and shape the stone slabs; a movable frame (5) that is installed on the fixed frame (2) and can move up and down along the pillars (21); a press plate (6) having a shape corresponding to the shape of the mold holder (3) to press the mold (4) tightly on the mold holder (3); a vibrating mechanism (7) mounted on the top side of the press plate (6) to transmit the vibration to press plate (6);a hanging rack (8) used for hanging the vibrating mechanism (7) which is permanently installed with the movable frame (5); wherein the hanging rack (8) has a structure consisting of three segments (8a, 8b, and 8c), and the incline angle between these segments (8a, 8b, and 8c) can be adjusted in accordance with the shape of the stone to be manufactured.

7. The equipment according to claim 6, wherein the two segments on both sides (8a, 8c) of the hanging rack (8) are installed in a way that is tilted downwards to manufacture curved-shaped stone.

8. The equipment according to claim 6 or 7, wherein the equipment has a plurality of vibrating mechanisms (7), and the vibrating mechanisms (7) are axial vibrating mechanisms that operate alternatively to transmit the vibration to each portion of the press plate (6).