Method and equipment for processing high porosity small slabs of stone

Abstract

The application relates to the technical field of stone processing, and particularly discloses a high-porosity small-plate stone processing method and equipment, which comprises the following steps: high-porosity stone plate hole type design, aluminum veneer layer and stone same-hole-type hole processing, aluminum veneer layer and stone layer combination reinforcement, stone plate long-side side surface through-groove processing, and decorative surface guide angle processing. The application solves the problems that the existing stone processing technology has high difficulty in decorative hole processing and the stone plate surface strength cannot meet the standards after the porosity is improved.

Description

Technical Field

[0001] This invention relates to the field of stone processing technology, specifically to a method and equipment for processing small slabs of stone with high porosity. Background Technology

[0002] Stone is a widely used material for high-end interior and exterior decoration. However, its hardness, brittleness, difficulty in processing, and heavy weight limit its application, both in terms of cost and safety. With socio-economic development and the continuous improvement of people's living standards, there are higher demands for the appearance, materials, connection structures, and functional effects of architectural decoration. How to improve the processing efficiency, quality, output, and safety of decorative stone, reduce processing costs and waste, conform to green building concepts, create richer stone aesthetic effects, and make buildings more innovative are questions that require in-depth research in the future development of stone material applications.

[0003] The current construction industry has raised demands for porous stone slabs, requiring the creation of multiple decorative holes to achieve desired aesthetic effects. These decorative holes are openwork designs with curved edges, their size and shape determined by the client's design requirements. The processing difficulty of this high-porosity stone lies in the fact that as the number of holes increases, the area and size of each hole complicate the stress distribution across the stone. Achieving the required strength standards while satisfying the desired stone slab design is one of the most pressing challenges in small-slab stone processing. Due to the unique physical properties of stone, compared to drilling holes in metal or compound slabs, drilling holes in stone requires more careful consideration of the hole size, shape, and location to ensure that the strength and deformation of the processed stone meet the relevant standards in GB / T 18601-2009 Natural Granite Building Slabs. Summary of the Invention

[0004] The present invention provides a method and equipment for processing small stone slabs with high porosity, in order to solve the problems of high difficulty in opening decorative holes and failure to meet the strength of stone slabs after increasing the porosity in existing stone processing technology.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a method and equipment for processing small stone slabs with high porosity, comprising the following steps:

[0006] Step 1: Prepare raw materials: Cut the stone material according to the design requirements to obtain stone slabs with a length of L1, a width of L2, and a thickness of T1. At the same time, prepare aluminum panels of the same size.

[0007] Step 2, Surface Treatment: Grind both sides of the stone slab to ensure flatness error ≤1.5mm and stone thickness error ±2mm; at the same time, roughen and passivate the surface of the aluminum panel.

[0008] Step 3, Drilling: The distance between each decorative hole on the stone surface and the edge of the stone is ≥40mm, and the distance between each decorative hole is kept within the range of 40~60mm. The distribution of decorative holes on the aluminum panel surface is the same as that on the stone surface. Drilling equipment is used to process the decorative holes on the stone and aluminum panel respectively.

[0009] Step 4, Adhesion: Use adhesive to adhere the passivated surface of the aluminum panel to the back of the stone;

[0010] Step 5, Static Pressing: Press the aluminum single panel and the stone together for 4-8 hours.

[0011] The basic principle of this solution is as follows: multiple irregular holes are designed and distributed on the stone slab according to the rule that they do not intersect each other and are more than 60mm apart and more than or equal to 40mm away from the edge of the stone slab. Based on this hole design, the aluminum panel is made by expanding the edge of the hole shape outward by 2-3mm. The stone and aluminum panel are then glued together and statically pressed for a period of time to keep the stone and aluminum panel flat and firmly bonded, ultimately forming a finished stone product that can be used for decoration.

[0012] The beneficial effects of this solution are as follows: it enables the processing of perforated, irregularly shaped holes on smaller stone slabs, improves the surface strength, toughness, durability, and reliability of the perforated stone, reduces the weight of the stone panel, extends the service life of the stone, ensures safe use, and can be used in more buildings with high aesthetic requirements. The processing has no requirements on the type of stone, and the finished perforated stone has wide applicability. It can create a perforated stone effect on indoor and outdoor decorative surfaces or, when combined with floodlighting, create a translucent stone effect, enhancing the building's aesthetic appeal. Perforated stone is best installed using full-length modular fasteners that match the depth and width of the long side groove.

[0013] Furthermore, in step 3, the drilling process should begin from the decorative stone surface and end from the back of the stone. Because the stone drilling device generates a significant impact force at the moment of cutting through the stone, it can easily cause chipping at the exit point of the blade. Therefore, the stone drilling process should begin from the decorative stone surface to reduce the defect rate of the finished product.

[0014] Furthermore, in step 3, the edge of the decorative hole on the aluminum panel is enlarged outward by 2-3 mm along the hole shape. To avoid hole position deviation or visible burrs in the stone holes during later bonding of the aluminum panel and stone, the inner diameter of the aluminum panel opening can be appropriately enlarged by 2-3 mm.

[0015] Furthermore, the process includes step 6, creating a through groove: creating a through groove on the long sidewall of the stone for installing a full-length modular hanger, ensuring the edge of the decorative hole in the through groove does not overlap with the orthographic projection trajectory of the through groove; step 7, processing bevels: beveling the four sides of the stone decorative surface, with bevels designed at other angles as needed; and step 8, protective treatment: applying liquid protective treatments such as anti-fouling, waterproofing, and anti-aging to the entire stone, followed by timely drying. Creating the through groove allows for a reliable and effective connection between the stone and the keel, while also allowing for adjustment of errors in the stone's movement (in, out, left, right), facilitating precision control during installation. This connection method also facilitates later maintenance and replacement of the stone. Bevel treatment reduces the probability of damage to the stone's edges during transportation and installation, increases aesthetics, and reduces the risk of injury from sharp stone edges. When multiple stone slabs need to be assembled at corners, the bevels can be designed at other angles as needed to ensure aesthetically pleasing gaps at the corners of the assembled stone. Chamfering should be performed together with grooving to reduce damage to the chamfered corners of the stone during processing and handling, thus minimizing impact on appearance quality.

[0016] Furthermore, the adhesive used in step 4 is marble adhesive. The passivated surface of the aluminum panel is firmly bonded to the back of the stone decorative surface using marble adhesive or similar bonding agents.

[0017] Furthermore, the process of determining the position of each decorative hole in step 3 includes: firstly designing a virtual square-shaped constraint line 40-60mm away from the edge of the stone on the stone surface; drawing a first decorative hole at each of the four corners of the square-shaped constraint line, with the edge of the first decorative hole being tangent to the square at most; expanding the edge of the first decorative hole outward by 40-60mm to form a virtual perforation influence line; expanding the edges of the remaining decorative holes to be located outward by 40-60mm to form a virtual perforation influence line; and ensuring that the perforation influence lines of all decorative holes are at most tangent to the actual edges of other decorative holes.

[0018] Furthermore, in step 6, the groove is L-shaped, with the height of the vertical section of the groove being H1 and the height of the horizontal section being H2, where H1-H2≥7mm. The groove width T2 is 1 / 3 to 1 / 4 of the stone thickness T1. The groove width and height ensure the safety of stone installation and use.

[0019] Furthermore, the drilling equipment in step 3 includes a drill bit and a freely movable support. The support includes a first arm and a second arm, and the drill bit includes a first drill bit, a second drill bit, and a third drill bit. The outer diameters of the first drill bit and the second drill bit are D1 and D2, respectively, where D1 < D2. The second drill bit has a vertical spline groove along its central axis inside. The upper section of the third drill bit is a spline section and can be keyed into the spline groove. The lower section of the spline section gradually expands outward to form a conical surface. The maximum outer diameter of the conical surface is D3, where D3 = D2. All three drill bits can be vertically installed on the opposite surfaces of the first arm and the second arm through drill bit sleeves. The drill bit sleeves on the first arm and the second arm are coaxially arranged. First, use the first drill bit to make a line cut along the inner edge of the opening. Then, insert the third drill bit from bottom to top into the opening of the first drill bit. Remove the first drill bit from the first arm and replace it with the second drill bit. The upper spline of the second drill bit and the third drill bit are connected. The second drill bit rotates, the first arm moves up, and the third drill bit moves upward. Its conical surface enters the stone slab and forms a conical surface at the bottom of the opening. Then, move the first arm down, and the second drill bit expands the opening outward. The entire decorative hole is now open. Since the conical surface of the third drill bit has already cut the bottom of the opening, the amount of stone brought down when the second drill bit exits is reduced, greatly reducing the phenomenon of edge chipping.

[0020] Furthermore, the side wall of the first arm is equipped with a clip for securing the drill bit. The drill bit to be used is clipped onto the first arm, preventing it from being lost due to carelessness and facilitating timely replacement by staff. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the stone opening design according to an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of the design of a stone groove according to an embodiment of the present invention;

[0023] Figure 3 This is a flowchart of the method of the present invention;

[0024] Figure 4 This is a schematic diagram of stone installation according to the present invention;

[0025] Figure 5 This is a schematic diagram of the drilling device in an embodiment of the present invention;

[0026] Figure 6 for Figure 5 A detailed schematic diagram of part A. Detailed Implementation

[0027] The following detailed description illustrates the specific implementation method:

[0028] The reference numerals in the accompanying drawings include: stone slab 1, stone opening edge influence line 2, stone perforation influence line 3, actual edge of hole 4, chamfer 5, through groove 6, aluminum single panel 7, first support arm 81, second support arm 82, first drill bit sleeve 91, second drill bit sleeve 92, first drill bit 101, second drill bit 102, third drill bit 103, first drill hole 121, tapered hole 122, inner edge of decorative hole 123.

[0029] The basic implementation examples are as follows: Figures 1 to 4 As shown:

[0030] Prepare stone slab 1: The side length should be 500-1500mm, the thickness should be 25-40mm, and the stone material, shape, hole type and size are not limited.

[0031] Design of the opening edge influence line: The opening edge influence line is a square frame, and each side should be 40mm away from the stone edge. When the area S of a single stone piece is greater than 1.5m2, the distance between the opening edge influence line and the stone edge should be increased to ensure that there are no perforations outside the stone edge influence line, and that the edge influence line does not coincide with the orthographic projection trajectory of the decorative surface of the effective depth H1 of the through groove 6. In this embodiment, for every 0.5m2 increase in the area of ​​a single stone piece, the distance between the opening edge influence line and the stone edge increases by 10mm.

[0032] Design of stone perforation influence line 3: Stone perforation influence line 3 is the basis for perforation design and processing. It is an imaginary trajectory line formed by the outward diffusion of the actual edge 4 of the stone perforation by 60mm. During the design and processing, the perforation influence line should not intersect or coincide with the actual edge 4 of the perforation, that is, the distance between adjacent perforations should not be less than 60mm.

[0033] Perforation: The distance between each decorative hole on the stone surface and the edge of the stone is ≥40mm, and the distance between each decorative hole is kept within 60mm. The distribution of decorative holes on the surface of aluminum single panel 7 is the same as that on the stone surface. The decorative holes on the stone and aluminum single panel 7 are processed separately using a drilling device.

[0034] Drilling equipment such as Figure 5 As shown, the U-shaped bracket is installed on a CNC machine tool. The bracket can move along the edge of the hole according to the design drawing of the decorative hole. The bracket includes a first horizontal support arm 81 at the upper end and a second horizontal support arm 82 at the lower end. Vertical drill bit sleeves are fixed on the opposite surfaces of the first support arm 81 and the second support arm 82. The drill bit sleeve is a common type of sleeve on hand drills used to clamp different drill bits. The drill bit sleeve on the first support arm 81 is the first drill bit sleeve 91. The first drill bit 101 and the second drill bit 102 can be detachably installed on the first drill bit sleeve 91. The drill bit sleeve on the second support arm 82 is the second drill bit sleeve 92. The third drill bit 103 can be detachably installed on the second drill bit sleeve 92.

[0035] The first drill bit 101 is a twist drill bit with a diameter of 10mm. The smaller diameter first drill bit 101 is fixed on the first drill bit 101 sleeve. The first drill bit should be 10mm away from the inner edge of the decorative hole. The drive bracket drives the first drill bit 101 to cut around the shape of the decorative hole to form the first drill hole 121.

[0036] The second drill bit 102 is a twist drill bit with a diameter of 20mm. It has an internal hole at its lower end, and an internal spline groove with a diameter of less than 10mm is provided inside the hole. The third drill bit 103 is similar to a conical drill bit. A spline shaft is coaxially provided at the upper end of the third drill bit 103. The lower end of the spline shaft is an outwardly extending conical surface. Multiple cutting tools are evenly distributed along its generatrix on the conical surface.

[0037] After the first drill hole 121 is formed, the drill bit on the first support arm 81 is replaced with the second drill bit 102. The third drill bit 103 is mounted on the second support arm 82. The second support arm 82 drives the splined shaft of the third drill bit 103 to extend into the first drill hole 121. The splined shaft extends through the first drill hole 121 and connects with the spline groove of the second drill bit 102, so that the third drill bit 103 can rotate synchronously with the second drill bit 102.

[0038] The second arm 82 continues to move upward, pushing the conical surface of the third drill bit 103 to enlarge the bottom of the first drill hole 121. The edge of the enlarged hole is just tangent to the final inner edge of the decorative hole. Then, the first arm 81 is driven to move downward, so that the third drill bit 103 is removed from the back of the stone. The second drill bit 102 drills downward. The drill hole formed by the second drill bit 102 is the second drill hole. The edge of the second drill hole is also tangent to the final inner edge of the decorative hole. When the second drill hole penetrates the stone and cuts around the inner edge 123 of the decorative hole, the entire decorative hole is processed.

[0039] The first drilled hole 121 is a pre-drilled hole with a smaller diameter. Compared with the original single-cutting method, the material on the back of the decorative hole is reduced, the volume of stone that can be moved when the knife exits is reduced, and the chipping area at the exit point shrinks. This reduces some of the tensile stress for later shaping and allows the third drill bit 103 to be inserted into the hole for enlargement. The conical hole 122 is formed by the conical surface of the third drill bit 103. The chipped area produced by the first drilled hole 121 is cleaned up, and the original chipped area is first shaped into the conical hole 122. The second drill bit 102 has a larger diameter and cuts through the stone again from top to bottom along the inner edge of the hole, so that the inner edge 123 of the decorative hole is finally shaped. Since its exit point has been pre-shaped, the second drill bit 102 no longer applies force to cause chipping, thereby improving the chipping problem caused by the original stone drilling technology.

[0040] The perforation shape is designed according to the above principles and actual needs. The shape and size distribution of the perforations determine the perforation processing of the stone slab 1 and the aluminum panel 7 on the back of the stone. To ensure that the inner diameter of the perforations in the stone and aluminum panels does not have burrs or other quality problems, and to ensure a good appearance of the perforated shape, the stone perforation starts from the decorative surface to reduce the risk of chipping at the perforation edge on the decorative surface. To reduce the difficulty of perforating the aluminum panel and the grinding cost, and to ensure that the back aluminum panel is not visible on the stone decorative surface, the inner diameter of the perforation in the aluminum panel can be enlarged outward by 2-3mm in the same shape. This ensures the reinforcement function of the aluminum panel and eliminates the perforation misalignment and burr problems that may occur when the stone and aluminum panels are pasted.

[0041] Through groove 6: The depth of through groove 6 on the decorative surface side is the effective depth H1, where H1 ≥ 14mm, and H1-H2 ≥ 7mm. The groove width T2 depends on the stone thickness and the thickness and size adjustment allowance of the matching combination hanger. In this embodiment, the groove width T2 is 1 / 4 of the stone thickness T1. The function of the perforated stone through groove 6 is to cooperate with the full-length combination hanger to fix the stone, such as... Figure 4 As shown, this full-length modular bracket is a common SE-type aluminum alloy bracket, which allows for a reliable and effective connection between the stone and the keel. It also allows for adjustment of the stone's movement in and out, as well as its vertical and horizontal errors, facilitating precision control during stone installation. Furthermore, this connection method makes it easier for the stone to be repaired and replaced later.

[0042] Chamfer 5: This refers to the chamfered corners 5 on all four sides of the stone decorative surface. The chamfer 5 can be 2×45°. This treatment reduces the probability of damage to the stone edges during transportation and installation, increases aesthetics, and reduces the risk of injury from the stone's sharp edges. When multiple stone slabs 1 need to be assembled at corners, the chamfer 5 can be designed with other angles according to actual needs, ensuring a beautiful appearance at the internal and external corners of the assembled stone, and that the stone decorative surface is parallel to the installation plane. The chamfer 5 processing should preferably be carried out together with the grooving 6 processing to reduce damage to the chamfer 5 during stone processing and handling, thus minimizing impact on the appearance quality.

[0043] Integrated bonding: Aluminum single-layer panel 7 is bonded to the back of the stone. The thickness of aluminum single-layer panel 7 should not be less than 1.5mm. When the stone area is greater than 1m², the thickness of the aluminum panel should be increased to ensure the flatness and strength of the stone. Before the above-mentioned perforation processing of the aluminum panel, the bonding surface of the aluminum panel should be roughened and passivated to increase the bonding force between the aluminum panel and the adhesive. After bonding, the stone and aluminum panel should be statically pressed for 4 hours to maintain the flatness and firm adhesion of the stone and aluminum panel.

[0044] Apply a protective layer: Apply a liquid protective treatment to the perforated stone to prevent staining, water damage, and aging, and dry it in time.

[0045] After completing the above processing steps, small stone slabs with high porosity are obtained.

[0046] The specific implementation process is as follows:

[0047] The U-shaped support can move longitudinally on the CNC machine tool, and the base of the drilling device can move laterally along the first and second supports. Through longitudinal and lateral movement, the drill bit can be made to correspond to different holes, and can travel along the design path of the decorative hole to process the decorative hole. When drilling, first install the first drill bit 101 and the third drill bit 103 on the U-shaped bracket, align the two drill bits on both sides of the stone where the hole needs to be drilled, start the first support arm 81 to drive the first drill bit 101 downward through the stone and drill the first drill hole 121, remove the first drill bit 101 and replace it with the second drill bit 102, then align the outer edge of the third drill bit 103 with the inner edge of the decorative hole when it is finally formed, start the second support arm 82 to drive the third drill bit 103 to extend out of the upper end of the stone, the spline shaft of the third drill bit 103 is keyed to the spline groove of the second drill bit 102, move the third drill bit 103 up to enlarge the bottom of the first drill hole 121 into a conical hole 122, and then move the second drill bit 102 down to enlarge the first drill hole 121 to the inner edge 123 of the decorative hole, and the decorative hole is finally formed.

[0048] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A method for processing high porosity small slabs of stone, characterized in that, It comprises the following steps: Step 1, preparing raw materials: cutting the stone raw material according to the size required by the design to obtain a plate stone with a length of L1, a width of L2 and a thickness of T1, and preparing an aluminum veneer with the same size; Step 2, surface treatment: polishing the front and back surfaces of the plate stone to ensure that the flatness error is ≤1.5mm and the stone thickness error is ±2mm; at the same time, performing roughening and passivation treatment on the surface of the aluminum veneer; Step 3, hole opening: the distance between the edges of each decorative hole on the surface of the stone and the edges of the stone is ≥40mm, and the distance between the edges of adjacent decorative holes is kept within the range of 40~60mm, the decorative hole distribution on the surface of the aluminum veneer is the same as that on the surface of the stone, and a punching equipment is used to process the decorative holes on the stone and the aluminum veneer respectively; Step 4, pasting: using an adhesive to paste the passivated surface of the aluminum veneer on the back of the stone; Step 5, static pressure: statically pressing the aluminum veneer and the stone pasted together for 4~8 hours; It also comprises step 6, opening a groove: opening a through groove for installing a through-combination type pendant on the long side wall of the stone, and the edge of the through groove decorative hole does not overlap with the orthographic projection track of the through groove on the stone decoration surface; Step 7, processing the guide angle: processing the guide angle for the four edges of the stone decoration surface, and the guide angle can be designed with other angles according to actual needs; Step 8, protection treatment: performing liquid protection treatment such as stain prevention, water prevention and aging resistance on the whole stone, and drying in time; The process of determining the positions of each decorative hole in step 3 comprises: first designing a virtual constraint line in the form of a square frame at a distance of 40~60mm from the edges of the stone; A first decorative hole is drawn at each of the four corners of the square constraint line, the edge of the first decorative hole is at most tangent to the square, the edge of the first decorative hole is expanded by 40~60mm to form a virtual perforation influence line, and the edges of the remaining to-be-positioned decorative holes are also expanded by 40~60mm to form virtual perforation influence lines, and the edges of the later-drawn decorative holes are at most tangent to the perforation influence lines of the earlier-drawn decorative holes; The through groove in step 6 is L-shaped, the height of the vertical section of the through groove is H1, the height of the horizontal section of the through groove is H2, H1-H2≥7mm, and the groove width T2 is 1 / 3~1 / 4 of the thickness T1 of the stone.

2. A method of processing high porosity small plate stone material according to claim 1, characterized in that: In step 3, the hole opening process should start from the stone decoration surface and end at the back of the stone.

3. The method of claim 1, wherein: In step 3, the edges of the actual decorative holes processed on the aluminum veneer are expanded outward by 2~3mm along the design decorative hole shape.

4. The method of claim 1, wherein: The adhesive in step 4 is a dolomite glue.

5. A high open porosity small plate stone material processing device, applied to the high open porosity small plate stone material processing method of any one of claims 1-4, characterized in that: The drilling device in the step 3 comprises a drill bit and a freely movable support, the support comprises a first supporting arm and a second supporting arm, the drill bit comprises a first drill bit, a second drill bit and a third drill bit; the outer diameters of the first drill bit and the second drill bit are D1 and D2 respectively, D1 < D2, the second drill bit is internally provided with a vertical spline groove along the axis thereof, the upper section of the third drill bit is a spline section and can be keyed connected in the spline groove, the lower section of the spline section is gradually outwardly expanded to form a tapered surface, a plurality of blades are uniformly distributed along the generatrix of the tapered surface in the circumferential direction, the maximum outer diameter of the tapered surface is D3, D3 = D2, the three drill bits can be vertically installed on the opposite surfaces of the first supporting arm and the second supporting arm through a drill bit sleeve, and the drill bit sleeves on the first supporting arm and the second supporting arm are coaxially arranged; when the first drill hole is formed, the drill bit on the first supporting arm is replaced by the second drill bit, and the third drill bit is installed on the second supporting arm; the spline shaft of the third drill bit is driven by the second supporting arm to extend into the first drill hole, the spline shaft extends out of the first drill hole and is in butt joint with the spline groove of the second drill bit, and the third drill bit rotates synchronously with the second drill bit; the second supporting arm moves upward to push the tapered surface of the third drill bit to expand the bottom end of the first drill hole, the edge of the expanded hole is tangent to the final inner edge of the decorative hole; the first supporting arm is driven to move downward, and the third drill bit is separated from the back surface of the stone; the second drill bit drills downward to form a second drill hole, and the edge of the second drill hole is tangent to the final inner edge of the decorative hole; the second drill hole penetrates the stone and cuts a circle along the inner edge line of the decorative hole.

6. A high-void-fraction small slabs stone processing apparatus according to claim 5, characterized in that: The side wall of the first supporting arm is provided with a buckle capable of fixing the drill bit.

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