A belt casting texture distribution process of textured ecological stone and textured ecological stone

Abstract

This invention discloses a belt-driven textured fabrication process for textured eco-stone and the resulting textured eco-stone. The process employs a slurry-based belt-driven textured fabrication device and includes the following steps: each hopper holds a different color of slurry; the discharge belt moves, and the slurry flows through the diversion holes of the diversion channel to the receiving belt; different colors of slurry from each fabrication module are discharged to the receiving belt according to a designed program, forming a color combination slurry; the color combination slurry is then filled into a mold via the casting belt and fabrication hopper to form a preset texture effect; the mold is then conveyed by a conveyor belt to the vibration and pressing processes; after primary curing, demolding, secondary curing, and polishing, an eco-stone product with a natural flowing texture is obtained. This invention's process controls the output amount and ratio via a belt conveyor, allowing different colors of slurry to flow and mix on the belt, thereby obtaining eco-stone products with rich colors, natural transitions, and smooth textures.

Description

Technical Field

[0001] This invention relates to the field of eco-stone technology, and in particular to a belt-cast textured fabric process for textured eco-stone and textured eco-stone. Background Technology

[0002] With the development of modern construction, consumers have placed demands on decorative materials that are lightweight, high-strength, aesthetically pleasing, and diverse. Eco-stone, which better aligns with the requirements of a circular economy and energy conservation and environmental protection, is gradually becoming the mainstream trend in the stone industry. Eco-stone products are also evolving from single, traditional products to meet the needs of multiple functions and uses. The preparation process of eco-stone products typically involves ingredient mixing, molding, and curing. The application of materials is divided into two processes: dry application and wet application.

[0003] Conventional dry fabric application involves mixing various raw materials with water to create a powder, which is then applied and vacuum-pressed to form various irregular textures and patterns. However, the powder has poor flowability, making it difficult to achieve seamless blending and transitions between different colors. Traditional wet fabric application involves mixing various raw materials with water to create a slurry, which is then cast to form textures and transitional colors. However, it suffers from limitations such as limited color variety, unstable textures, and numerous air pockets. Summary of the Invention

[0004] The purpose of this invention is to propose a belt-draped textured fabric process for textured eco-stone. By using a belt-draped fabric method, multiple colors of paste are drawn on the belt to form textured paste and transition colors, thereby obtaining textured eco-stone. Based on matching different colored pastes, textured eco-stones with various decorative effects can be obtained.

[0005] The purpose of this invention is to propose a textured eco-stone that uses a wet fabric molding process, resulting in a smooth, non-porous surface and diverse decorative effects.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A textured eco-stone belt casting process is disclosed. This process utilizes a textured fabrication device comprising multiple fabrication modules arranged side-by-side. Each fabrication module includes a hopper, a gate assembly, a discharge belt, and a diversion trough. The hopper is located above the discharge belt, the gate assembly is positioned between the hopper and the discharge belt, and the diversion trough is located below the port of the discharge belt. A receiving belt is positioned below the fabrication modules, and below the receiving belt are a casting belt, a fabrication hopper, and a mold conveyor belt.

[0008] The process includes the following steps:

[0009] (1) Material preparation: Prepare slurries of various colors;

[0010] (2) Each fabric module has a hopper containing a slurry of a certain color. The discharge belt moves at a set speed, which drives the slurry in the hopper to be discharged from the gate assembly and fall into the diversion trough. The diversion trough has multiple diversion holes. The slurry is discharged from the diversion holes to the receiving belt. The slurry in each fabric module is discharged to the receiving belt at the same time according to the design ratio, forming a color combination slurry on the receiving belt.

[0011] (3) The color combination paste is fed to the casting belt via the receiving belt, and then falls into the cloth hopper via the casting belt. The color combination paste in the cloth hopper is evenly filled into the mold on the mold conveyor belt.

[0012] (4) While the casting belt drives the slurry to fall into the fabric hopper, the mold conveyor belt drives the mold to move, so that the color combination slurry is evenly filled into the mold, forming a textured fabric effect in the mold.

[0013] (5) After the color combination slurry fills the mold, the mold is sent to the vibration process and pressing process by the conveyor belt. Then, after primary curing, demolding, secondary curing and polishing, an eco-stone product with textured decoration is obtained.

[0014] Furthermore, in step (2), the multiple diversion holes of the diversion grooves of different fabric modules are staggered and / or overlapped along the conveying direction of the receiving belt;

[0015] After the color pastes from the different fabric modules are discharged according to the design ratio, they are fed onto the receiving belt through the diversion channel of each fabric module. The different color pastes are interleaved and / or superimposed to form a color combination paste.

[0016] Furthermore, a diversion device is provided between the receiving belt and the casting belt, and between the casting belt and the fabric hopper;

[0017] In step (3), when the color combination slurry passes through the diversion device, the slurries of different colors in the color combination slurry are cast, dispersed and fused.

[0018] Furthermore, the diversion device includes multiple flow guides, with a diversion hole formed between two adjacent flow guides.

[0019] Furthermore, the fabric hopper is equipped with a moving mechanism;

[0020] In step (3), while the color combination paste is being filled into the mold, the moving mechanism drives the cloth hopper to swing left and right along the direction perpendicular to the mold conveying direction. The color combination paste is filled into the mold through the cloth hopper, forming diagonal or wavy patterns in the mold.

[0021] Furthermore, the fabric hopper is provided with multiple dividing strips, which divide the internal space of the fabric hopper into multiple small areas for material feeding. After the color combination paste enters the fabric hopper, it flows out from the small areas.

[0022] Furthermore, after preparing the slurry, the slurry's fluidity is tested. Step (2) is only performed after the slurry's fluidity test is passed. The fluidity of the slurry is 60-70%, and the method for testing the fluidity of the slurry is as follows:

[0023] A measured amount of slurry is injected into an open container and weighed as W1. The weight of the open container is w. Then, the open container is rotated 90° and the slurry is poured out from the top opening of the open container.

[0024] Start timing while flipping the open container. After 30 seconds, flip the open container back into place and weigh it as W2.

[0025] The formula for calculating the fluidity of the slurry is: [(W1-W2) / (W1-w)]×100%.

[0026] Furthermore, the raw materials of the slurry, by weight, include:

[0027] 25-30 parts white cement, 10-20 parts 26-40 mesh sand, 20-30 parts 40-70 mesh sand, 10-20 parts 70-120 mesh sand, 5-10 parts 100-200 mesh sand, 5-10 parts 300-500 mesh sand powder, 5-10 parts 1000-2000 mesh sand powder, 1-3 parts activated kaolin, 3-5 parts activated silica powder, and 1-3 parts water-based emulsion;

[0028] Based on the amount of white cement used, the raw materials for the slurry also include:

[0029] Whiskers 10-30 g / kg white cement, alkali inhibitor 10-30 g / kg white cement, defoamer 3-6 g / kg white cement, water reducer 5-10 g / kg white cement, rheology modifier 3-6 g / kg white cement;

[0030] The raw materials of the slurry have a ash-sand ratio of 2.0-3.0.

[0031] Furthermore, the method for preparing the color paste is as follows:

[0032] According to the formula, white cement, activated silica powder, activated kaolin, whiskers, alkali inhibitor, defoamer, water-reducing agent, color powder, rheology modifier and 26-40 mesh sand are mixed evenly to obtain premixed dry material.

[0033] Add water and water-based emulsion to the premixed dry material, stir to form a slurry, then add sand according to the formula amount, and stir evenly to obtain the color slurry.

[0034] A textured eco-stone is prepared using a belt-cast textured fabric process.

[0035] The technical solution provided by this invention may include the following beneficial effects:

[0036] 1. The process of this invention uses a belt-and-cloth method to obtain eco-stone, which makes the eco-stone have a smooth and flat surface while having a richer decorative effect.

[0037] 2. The eco-stone obtained by the process of the present invention is an eco-stone with full decoration. After cutting, grooving or carving, the internal texture of the eco-stone with full decoration can be seen through, and the eco-stone has a better simulation effect and is more suitable for processing.

[0038] 3. Instead of dropping the slurry directly onto the mold, the slurry is transferred via a casting belt. After being transferred by the casting belt, the slurry has smoother lines, eliminating wavy edges on the lines and textures. Different colors of slurry can blend better and improve the smoothness of the texture.

[0039] 4. By using a diversion device to disperse and refine overlapping and / or spaced color bands, the softness and randomness of the lines are improved, resulting in richer lines and textures in the eco-stones and helping them achieve a realistic effect.

[0040] 5. Above the mold conveyor belt is a cloth hopper, which makes the strip texture inside the mold bend into an arc shape, enriching the decorative effect of the texture;

[0041] 6. The cement slurry is poured out of the container, a fixed pouring time is set, and the weight difference before and after pouring is calculated to determine the fluidity of the cement slurry. This method is more reliable and helps to obtain a better spreading effect.

[0042] 7. Using white cement as the main material, whiskers, sand and sand powder are added to increase the strength of the ecological stone. Activated kaolin, activated silica powder, water-based emulsion and rheology modifiers are used to improve the viscosity of the slurry, thereby improving the smoothness and casting effect of the slurry. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of a textured fabric device according to an embodiment of the present invention;

[0044] Figure 2 This is a schematic diagram showing the flow diversion device and the material hopper working in conjunction with the belt;

[0045] Figure 3 This is a schematic diagram of the diversion channel;

[0046] Figure 4 The photo shows a product made using a textured eco-stone belt-cast textured fabric process.

[0047] The components include: fabric module 1, hopper 11, discharge belt 12, diversion trough 13, diversion hole 131, receiving belt 2, casting belt 3, mold conveyor belt 4, mold 5, diversion device 6, and fabric hopper 7. Detailed Implementation

[0048] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0049] In the description of this invention, it should be understood that the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, features defined with "first" and "second" may explicitly or implicitly include one or more of these features, used to distinguish and describe features, without any order or emphasis.

[0050] In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0051] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0052] See Figure 1 and Figure 3A textured eco-stone belt casting textured fabric process is disclosed. This process utilizes a textured fabrication device comprising multiple fabrication modules 1 arranged side-by-side. Each fabrication module 1 includes a hopper 11, a gate assembly, a discharge belt 12, and a diversion trough 13. The hopper 11 is located above the discharge belt 12, and the gate assembly is positioned between the hopper 11 and the discharge belt 12. A receiving belt 2 is located below the fabrication module 1, and below the receiving belt 2 are a casting belt 3, a fabrication hopper 7, and a mold conveyor belt 4.

[0053] The process includes the following steps:

[0054] (1) Material preparation: Prepare slurries of various colors;

[0055] (2) Each fabric module 1 has a hopper 11 filled with a slurry. The discharge belt 12 moves at a set speed, driving the slurry in the hopper to be discharged from the gate assembly and fall into the diversion trough 13. The diversion trough 13 has multiple diversion holes 131. The slurry is discharged from the diversion holes 131 to the receiving belt 2. The slurry in each fabric module 1 falls into the receiving belt 2 at the same time according to the design ratio, forming a color combination slurry on the receiving belt 2.

[0056] (3) The color combination paste is fed to the casting belt 3 via the receiving belt 2, and then falls into the cloth hopper via the casting belt 3. The color combination paste in the cloth hopper is evenly filled into the mold 5 on the mold conveyor belt 4.

[0057] (4) While the casting belt 3 drives the slurry to fall, the mold conveyor belt 4 drives the mold 5 to move, so that the slurry is evenly spread in the mold 5, forming a striped textured fabric effect in the mold 5.

[0058] (5) After the color combination slurry is spread to the mold 5, the mold is sent to the vibration process and pressing process by the conveyor belt. Then, after primary curing, demolding, secondary curing and polishing, an ecological stone product with texture decoration is obtained.

[0059] Based on the limitations of existing wet-laid fabrics in terms of decorative effect, this invention provides a belt-cast textured fabric process for textured eco-stone. In this invention, multiple colors of slurry are first cast in strips onto a receiving belt 2, forming a multi-colored, interlaced strip textured slurry, i.e., a color combination slurry. This slurry then falls onto a moving mold 5 via a casting belt 3. Once the mold 5 is full of slurry, the next mold 5 is filled. The mold 5 filled with slurry then enters a curing process, and demolding yields the textured eco-stone.

[0060] Understandably, the slurry in this technical solution is cement slurry. Cement slurry has fluidity and a certain viscosity. After falling from the diversion trough 13 to the receiving belt 2, the cement slurry forms a strip-shaped material area on the receiving belt 2. The slurry from multiple hoppers 11 has a relatively clear boundary on the receiving belt 2, so as to form a color combination slurry on the receiving belt 2, thereby achieving textured material distribution. The slurry is spread evenly on the belt plane, and the slurry layer thickness is uniform when falling into the mold 5, making the material distribution easier to control. It should be noted that there are baffles on both sides of the discharge belt 12, the receiving belt 2, and the casting belt 3 to prevent slurry overflow.

[0061] Specifically, multiple fabric modules 1 are arranged side-by-side along the conveying direction of the receiving belt 2. The paste from these multiple side-by-side fabric modules 1 falls sequentially onto the receiving belt 2, allowing multiple colors of paste to be superimposed or filled one by one, forming a layered striped texture. By adjusting the amount of paste fed into each fabric module 1, the background color, main texture color, and secondary texture color can be set to create a more decorative texture pattern. For example, along the conveying direction of the receiving belt 2, the background color fabric module 1 is fed first, with a large amount of paste; then comes the main texture color fabric module 1, followed by the secondary texture color fabric module 1. The background color paste is spread over a large area on the receiving belt 2, and the main texture color paste is superimposed on the background color paste to create thick lines or multiple lines. Then, the secondary texture color paste is superimposed on the background color paste and interspersed or superimposed with the main texture color paste, forming a smooth color combination paste on the receiving belt 2. Understandably, in some embodiments, the number of fabric modules 1, the order of various colored pastes, and the amount of material fed are set according to the resulting ecological stone texture, to produce ecological stones with diverse decorative effects that imitate natural stone, flowing water, and other colored textures. Preferably, the conveying direction of the discharge belt 12 is opposite to the conveying direction of the receiving belt 2 to shorten the length of the fabric line.

[0062] This technology uses a casting belt 3 to cast the paste, instead of directly dropping the paste from the receiving belt 2 onto the mold 5. Preferably, the angle between the conveying surface of the casting belt 3 and the horizontal plane is 30° to 45°, and the lower end of the conveying surface of the casting belt 3 is located above the fabric hopper. The angled casting belt 3 allows the color combination paste to flow and mix on the casting belt 3, producing more composite colors, resulting in natural and rich textures in the product. Moreover, the paste has smoother lines after being cast by the casting belt 3, eliminating wavy edges in the texture, and allowing the different colors of paste to blend better. In addition, based on the transfer function of the casting belt 3, the thickness of the paste on the belt can be made more uniform, improving the accuracy of the amount of paste dispensed into the mold 5. Furthermore, by adjusting the speed difference between the receiving belt 2 and the casting belt 3, the conveying speed of the casting belt 3 can be made greater than that of the receiving belt 2, which can elongate and refine the texture of the paste, further improving the smoothness of the texture.

[0063] Since the eco-stone has a certain thickness, the thickness of the eco-stone is determined by adjusting the thickness of the slurry on the casting belt 3 and the number of times the material is spread on the mold 5. The bottom end of the hopper 11 has a gate assembly. The width of the outlet of the gate assembly is adapted to the width of the discharge belt 12 so that the slurry can be evenly spread on the receiving belt 2. By adjusting the opening of the outlet, the thickness of the slurry on the discharge belt 12 can be adjusted, thereby adjusting the thickness of the slurry on the receiving belt 2, and thus adjusting the thickness of the slurry on the casting belt 3.

[0064] The eco-stone obtained by the process of this invention is an eco-stone with full-body decoration. This is because the slurry from multiple fabric modules 1 is laid on the receiving belt 2 in a casting manner. After passing through the casting belt 3, the slurry of different colors has a better fusion effect, and the texture can penetrate into the main body, thus obtaining an eco-stone with full-body decoration. After cutting, grooving, or carving, the internal texture of the eco-stone with full-body decoration can be seen through, resulting in a better simulation effect and making it more suitable for processing.

[0065] Optionally, the bottom surface of mold 5 can be flat or have linear raised textures. When the bottom surface of mold 5 has linear raised textures, the surface of the resulting eco-stone also has raised textures, resulting in a richer decorative effect. In some embodiments, the width and position of the linear raised textures on the bottom surface of mold 5 correspond to the texture of the slurry on the casting belt 3, so that the raised texture and color texture of the resulting eco-stone complement each other, resulting in a more dynamic decorative effect. Understandably, the protrusion height and depression depth of the raised texture are set according to specific circumstances.

[0066] Furthermore, in step (2), the multiple diversion holes 131 of the diversion grooves 13 of different fabric modules 1 are staggered and / or overlapped along the conveying direction of the receiving belt 2.

[0067] After the color pastes from different fabric modules 1 are discharged according to the design ratio, they are fed onto the receiving belt 3 via the diversion channel 13 of each fabric module 1. The different color pastes are interleaved and / or superimposed to form a color combination paste.

[0068] In a preferred embodiment of the present invention, the multiple diversion holes 131 of the diversion groove 13 are spaced apart to ensure that the slurry of one color has a certain spacing after falling from the multiple diversion holes 131, preventing two adjacent slurry bands from contacting or overlapping, which is beneficial to obtaining a clear texture. In addition, the distribution width of the diversion holes 131 of the multiple diversion grooves 13 along the feeding direction of the receiving belt 2 corresponds to the width of the receiving belt 2, so that the diversion holes 131 of the multiple diversion grooves 13 can basically fill the receiving belt 2 along the width of the receiving belt 2, so as to ensure that the slurry thickness on the receiving belt 2 is relatively uniform, and also to prevent the line texture from being overly spread in the transverse direction of the receiving belt 2, which would affect the decorative effect of the line texture. Furthermore, the diversion holes 131 of multiple diversion channels 13 are staggered and / or overlapped along the feeding direction of the receiving belt 2. When the diversion holes 131 of different diversion channels 13 overlap along the feeding direction of the receiving belt 2, different colored slurries overlap, forming a color superposition effect after passing through the casting belt 3. When the diversion holes 131 of different diversion channels 13 are staggered along the feeding direction of the receiving belt 2, the two colors of pigment are parallel, forming parallel lines with intervals. In the same embodiment, the overlapping and staggering of several diversion holes 131 of different diversion channels 13 along the feeding direction of the receiving belt 2 can obtain a full textured decorative effect.

[0069] See Figure 1 and Figure 2 Furthermore, there are flow diversion devices 6 between the receiving belt 2 and the casting belt 3, and between the casting belt 3 and the mold conveyor belt 4;

[0070] In step (3), when the color combination slurry passes through the diversion device 6, the slurries of different colors in the color combination slurry undergo casting, dispersion and fusion.

[0071] In some embodiments of the present invention, in order to improve the smoothness and randomness of the lines, the overlapping and / or spaced color bands are dispersed by the diversion device 6. For example, four color bands on the receiving belt 2 are dispersed and become thinner. The combination relationship of the color bands can also be adjusted, i.e., fused. The thickness and combination of the color bands are more random, the lines and textures of the eco-stone are richer, and it is also beneficial to make the eco-stone achieve a simulation effect.

[0072] Furthermore, the diversion device 6 includes a plurality of guide elements, and a diversion hole is formed between two adjacent guide elements.

[0073] In the technical solution of this invention, a flow guide is used to disperse the linear texture of the slurry. When the slurry passes through the rod, it flows downward from both sides of the flow guide, and the dispersed texture is further compressed and recombine to form a multi-colored texture. The degree of slurry dispersion is adjusted by setting the number and diameter of the flow guides. Preferably, the flow guide is a rod, an oblique plate, or a spiral plate; the two flow distribution devices may also be provided with an outer frame, and multiple flow guides are fixed side by side at the bottom of the outer frame.

[0074] Understandably, in one embodiment, if the slurry has only one background color, one main texture color, and one secondary texture color, and the main texture color and secondary texture color are superimposed and spaced parallel on the receiving belt 2, after passing through the two diversion devices 6, the main texture color and secondary texture color will form fine line textures, and the distribution, superposition, and spacing of the two main texture colors and secondary texture colors on the background color will be more random, and the texture will not be rigid, but more dynamic.

[0075] In a further preferred embodiment, the distance between the tail ends of two adjacent guide components is greater than the distance between the front ends, rather than setting all guide components in parallel. This can disperse and blend the texture of the parallel conveyed slurry, thereby further improving the randomness of the texture and the superposition effect of rich multi-colored lines.

[0076] See Figure 1 and Figure 2 Furthermore, the fabric hopper 7 is equipped with a moving mechanism;

[0077] In step (3), while the color combination paste is being filled into the mold, the moving mechanism drives the fabric hopper 7 to swing left and right along a direction perpendicular to the paste conveying direction. After passing through the fabric hopper 7, the color combination paste is filled into the mold 5, forming a diagonal or wavy pattern within the mold 5. This ensures that the texture effect of the color combination paste from the fabric hopper to the mold remains stable, continuous, and consistent in texture style (as shown in the product). Figure 4 (As shown).

[0078] Specifically, the feeding hopper 7 can adjust the drop position of the slurry in the mold 5. While feeding, the feeding hopper 7 swings left and right along a direction perpendicular to the conveying direction, which can make the feeding of the slurry continuous, thus forming diagonal or wavy patterns in the mold 5. By adjusting the moving distance and moving speed of the feeding hopper 7, the curvature of the diagonal or wavy patterns can be controlled.

[0079] Furthermore, the fabric hopper 7 is provided with multiple dividing strips, which divide the internal space of the fabric hopper 7 into multiple small areas for material feeding. After the color combination paste enters the fabric hopper 7, it flows out from the small areas. The multiple dividing strips can change the falling path of the paste and disperse and blend the striped texture.

[0080] As the feed hopper 7 moves perpendicular to the conveying direction, the slurry falls from the small feeding area into the mold 5. Multiple parallel dividing strips alter the slurry's falling path, causing it to deflect. The deflection speed can be adjusted by changing the gap between adjacent dividing strips and by adjusting the diameter of the dividing strips. It should be noted that the gap between adjacent dividing strips should not be too large, otherwise the deflection effect will be difficult to achieve; nor should it be too small, otherwise it will obstruct the feeding. Preferably, the gap width between adjacent dividing strips is 5-10 cm.

[0081] In the technical solution of this invention, a fabric hopper 7 with dividers is used to deflect the falling slurry to obtain a twill or wavy pattern, rather than forming an arc-shaped texture by moving a belt. The texture lines formed by the fabric hopper 7 with a rod are smoother, and the color transition of the texture is more natural.

[0082] Understandably, the opening width of the cloth hopper 7 is greater than the width of the casting belt 3 to ensure that all the slurry can fall into the cloth hopper 7.

[0083] Furthermore, after preparing the slurry, the slurry's fluidity is tested. Step (2) is only performed after the slurry's fluidity test is passed. The fluidity of the slurry is 60-70%, and the method for testing the fluidity of the slurry is as follows:

[0084] A measured amount of slurry is injected into an open container and weighed as W1. The weight of the open container is w. Then, the open container is rotated 90° and the slurry is poured out from the top opening of the open container.

[0085] Start timing while flipping the open container. After 30 seconds, flip the open container back into place and weigh it as W2.

[0086] The formula for calculating the fluidity of the slurry is: [(W1-W2) / (W1-w)]×100%.

[0087] The existing method for testing the fluidity of slurries involves placing a fixed volume of slurry in a funnel, starting a timer as soon as the outlet at the bottom of the funnel is opened, and stopping the timer when the slurry has completely flowed out. The time difference is then recorded, and this time difference characterizes the fluidity of the slurry. Slurry fluidity calculated in this way is often measured in seconds. This method is commonly used in the ceramics industry for testing glaze slurries and body slurries, as ceramic slurries have excellent fluidity, and this fluidity test yields reliable results.

[0088] Eco-stone uses cement as a binder, and the slurry of this invention is a cement slurry. Cement slurry differs from slurries used in the ceramics industry in terms of characteristics; its fluidity is inferior, and the sand particles in cement slurry are larger. Using existing slurry fluidity testing methods would lead to inaccurate test data and could also clog the funnel outlet, preventing the test from being completed. However, this invention uses a belt conveyor for material distribution, and a smooth slurry flow is required to obtain high-quality eco-stone, which places high demands on the slurry's fluidity. Therefore, this technical solution provides a fluidity testing method for cement slurry to achieve the testing of its fluidity.

[0089] In this invention, cement slurry is poured out of a container at a fixed time, and the weight difference before and after pouring is calculated to determine the slurry's fluidity. Cement slurry is more viscous than slurries used in ceramics, resulting in a tendency to adhere to the container walls. The amount of this adhesion is calculated to determine the slurry's fluidity; more adhesion indicates poorer fluidity. In this invention, a slurry fluidity of 60-70% achieves a better spreading effect.

[0090] Furthermore, the raw materials of the slurry, by weight, include:

[0091] 25-30 parts white cement, 10-20 parts 26-40 mesh sand, 20-30 parts 40-70 mesh sand, 10-20 parts 70-120 mesh sand, 5-10 parts 100-200 mesh sand, 5-10 parts 300-500 mesh sand powder, 5-10 parts 1000-2000 mesh sand powder, 1-3 parts activated kaolin, 3-5 parts activated silica powder, and 1-3 parts water-based emulsion;

[0092] Based on the amount of white cement used, the raw materials of the slurry also include: whiskers 10-30 g / kg white cement, alkali inhibitor 10-30 g / kg white cement, defoamer 3-6 g / kg white cement, water reducer 5-10 g / kg white cement, and rheology modifier 3-6 g / kg white cement.

[0093] The raw materials of the slurry have a cement-sand ratio of 2.0-3.0, that is, the ratio of the sum of the weight of sand and sand powder to the weight of white cement is 2.0-3.0.

[0094] In one embodiment of the present invention, white cement is used as the main material, and whiskers, sand and sand powder are added to increase the strength of the ecological stone. Activated kaolin, activated silica powder, water-based emulsion and rheology modifier are used to improve the viscosity of the slurry, thereby improving the smoothness and casting effect of the slurry. Preferably, the rheology modifier is hydroxypropyl methylcellulose or polysaccharide.

[0095] In this scheme, the sand used is quartz sand or calcium carbonate sand, and the sand powder is quartz powder or calcium carbonate powder. It should be noted that the raw materials for the slurry also include colorants. Different colors of slurry are obtained by using different colorants. If no colorants are added, the resulting slurry will be white.

[0096] Furthermore, the method for preparing the slurry is as follows:

[0097] According to the formula, white cement, activated silica powder, activated kaolin, whiskers, defoamer, water-reducing agent, color powder, rheology modifier and 26-40 mesh sand are mixed evenly to obtain premixed dry material.

[0098] Water and aqueous emulsion are added to the premixed dry material, stirred to form a slurry, and then sand is added according to the formula amount and stirred evenly to obtain the slurry.

[0099] In this invention, cement and small granules are first mixed, then water is added to form a slurry, and finally sand is added to ensure the uniformity of the raw material mixture.

[0100] Accordingly, the present invention also provides a textured eco-stone, which is prepared using the above-mentioned textured eco-stone belt casting textured fabric process. This textured eco-stone has good decorative effect, smooth surface, and diverse decorative textures.

[0101] The present invention is further illustrated below through examples.

[0102] Example 1: Belt-cast textured fabric process for textured eco-stone

[0103] Example 1-1

[0104] The process employs a textured fabric spreading device, which includes multiple fabric spreading modules 1 arranged side by side. Each fabric spreading module 1 includes a hopper 11, a gate assembly, a discharge belt 12, and a diversion trough 13. The hopper 11 is located above the discharge belt 12, the gate assembly is positioned between the hopper 11 and the discharge belt 12, and the diversion trough 13 is positioned below the port of the discharge belt 12. A receiving belt 2 is positioned below the fabric spreading module 1, and a casting belt 3, a fabric spreading hopper 7, and a mold conveyor belt 4 are positioned below the receiving belt 2.

[0105] The process includes the following steps:

[0106] Step (1) Material preparation: Prepare slurries of various colors;

[0107] After preparing the slurry, its fluidity is tested. Step (2) is only performed after the slurry's fluidity is deemed acceptable. The fluidity of the slurry should be 60-70%. The method for testing the fluidity of the slurry is as follows:

[0108] A measured amount of slurry is injected into an open container and weighed as W1. The weight of the open container is w. Then, the open container is rotated 90°, and the slurry is poured out from the top opening of the open container. Timing starts while rotating the open container. After 30 seconds, the open container is rotated back to its original position and weighed as W2. The formula for calculating the fluidity of the slurry is: [(W1-W2) / (W1-w)]×100%.

[0109] Step (2) fills the hopper 11 of each fabric module 1 with a slurry. The discharge belt 12 moves at a set speed, driving the slurry in the hopper 1 to be discharged from the gate assembly and fall into the diversion trough 13. The diversion trough 13 has multiple diversion holes 131. The slurry is discharged from the diversion holes 131 to the receiving belt 2. The slurry in each fabric module 1 is discharged to the receiving belt 2 at the same time according to the design ratio, forming a color combination slurry on the receiving belt 2.

[0110] Multiple diversion holes 131 of the diversion channels 12 of different fabric modules 1 are staggered and / or overlapped along the conveying direction of the receiving belt 2; after the color paste in different fabric modules 1 is discharged according to the design ratio, it is fed onto the receiving belt 2 through the diversion channels 13 of each fabric module 1, and the different color pastes form an interlaced and / or superimposed combination to form a color combination paste.

[0111] Step (3) The color combination paste is fed from the receiving belt 2 to the casting belt 3, and then falls into the cloth hopper 7 via the casting belt 3. The material from the cloth hopper 7 is evenly filled into the mold 5 on the mold conveyor belt 4.

[0112] In step (4), the casting belt 3 pulls the slurry down to the cloth hopper, while the mold conveyor belt 4 pulls the mold 5 to move, so that the color combination slurry is evenly spread in the mold 5, forming a striped texture cloth effect in the mold 5.

[0113] After the color combination slurry is spread to the mold 5 in step (5), the mold is sent to the vibration process and pressing process by the conveyor belt. Then, after primary curing, demolding, secondary curing and polishing, an eco-stone product with textured decoration is obtained.

[0114] The eco-stone obtained through the above steps in this embodiment has a striped texture decoration throughout. The striped texture is straight and relatively thick, but can be set with a variety of color bands, and has a general decorative effect.

[0115] Examples 1-2

[0116] This embodiment is basically the same as the process in embodiment 1-1, except that there is a flow divider 6 between the receiving belt 2 and the casting belt 3, and between the casting belt 3 and the mold conveyor belt 4; in step (3), when the color combination slurry passes through the flow divider 6, the striped texture is dispersed and merged. Specifically, the flow divider 6 includes multiple guide elements, and a flow divider hole is formed between two adjacent guide elements.

[0117] The eco-stone obtained through the above steps in this embodiment has a striped texture decoration throughout. The stripes are straight and vary in thickness, with good smoothness. The colors blend well, and a variety of color bands can be set, resulting in a good decorative effect.

[0118] Examples 1-3

[0119] This embodiment is basically the same as the process of embodiments 1-2. The difference is that the cloth hopper 7 is equipped with a moving device. In step (3), while the slurry falls, the cloth hopper 7 moves along a direction perpendicular to the slurry conveying direction. After passing through the cloth hopper 7, the slurry is laid in the mold 5 and forms a diagonal or wavy pattern in the mold 5.

[0120] Specifically, the fabric hopper 7 is equipped with multiple dividing strips, which divide the internal space of the fabric hopper 7 into multiple small areas for material feeding. After the color combination paste enters the fabric hopper 7, it flows out from the small areas. The multiple dividing strips can change the falling path of the paste and disperse and blend the striped texture.

[0121] The eco-stone obtained through the above steps in this embodiment has a continuous striped texture decoration, as shown in the reference. Figure 4 The striped texture is curved and varies in thickness, with good smoothness and excellent blending effect of different colors. It can be set with a variety of color bands, has a good decorative effect, and can also achieve the effect of imitating natural stone.

[0122] Example Group 2 Textured Ecological Stone

[0123] The formula for the textured eco-stone in this embodiment is shown in the table below.

[0124]

[0125]

[0126] The formulations of Examples 2-1 to 2-5 above were prepared into slurries using the following method:

[0127] According to the formula, white cement, activated silica powder, activated kaolin, whiskers, alkali inhibitor, defoamer, water-reducing agent, color powder, rheology modifier and 26-40 mesh sand are mixed evenly to obtain premixed dry material.

[0128] Water is added to the premixed dry material, and the mixture is stirred to form a slurry. Then, other sands are added according to the formula, and the mixture is stirred evenly to obtain the slurry.

[0129] By applying the above-mentioned slurry in Example Group 1, eco-stones with various decorative effects can be obtained.

[0130] Other components and operations of the textured eco-stone belt casting textured fabric process according to an embodiment of the present invention are known to those skilled in the art and will not be described in detail here.

[0131] In the description of this specification, references to terms such as "embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0132] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A belt cast textured fabric process for textured eco-stone, characterized by, The process adopts a texture distribution device, which comprises a plurality of distribution modules arranged side by side, each of the distribution modules comprising a hopper, a gate assembly, an outfeed belt and a distribution tank, the hopper being located above the outfeed belt, the gate assembly being arranged between the hopper and the outfeed belt, and the distribution tank being arranged below the port of the outfeed belt; A receiving belt is arranged below the distribution modules, and a flow belt, a distribution hopper and a mold conveying belt are arranged below the receiving belt. The process comprises the following steps: (1) Preparation: preparing a plurality of slurries of different colors; (2) Each of the hoppers of the distribution modules is filled with a slurry of a color, and the outfeed belt is operated at a set speed to move, thereby driving the slurry in the hopper to be discharged from the gate assembly and fall into the distribution tank, the distribution tank being provided with a plurality of distribution holes, the slurry being discharged from the distribution holes to the receiving belt, and the slurries in each of the distribution modules being simultaneously discharged to the receiving belt at a designed ratio to form a color combination slurry on the receiving belt; (3) The color combination slurry is sent to the flow belt through the receiving belt, and then falls to the distribution hopper through the flow belt, the color combination slurry in the distribution hopper being uniformly filled in the molds on the mold conveying belt; (4) While the flow belt drives the slurry to fall to the distribution hopper, the mold conveying belt drives the molds to move, so that the color combination slurry is uniformly filled in the molds to form a texture distribution effect in the molds; (5) After the color combination slurry fills the molds, the molds are sent to a vibrating process and a pressing process by the conveying belt, and then are subjected to primary curing, demolding, secondary curing and polishing to obtain an ecological stone product with a texture decoration.

2. The belt cast textured veining process for textured eco-stone of claim 1, wherein, In step (2), the plurality of distribution holes of the distribution tanks of different distribution modules are arranged in a staggered manner and / or an overlapped manner along the conveying direction of the receiving belt; After the color slurries in different distribution modules are discharged at a designed ratio, the color slurries are discharged to the receiving belt through the distribution tanks of the distribution modules, and the color slurries are formed in an interlaced and / or superimposed combination to form a color combination slurry.

3. The belt cast textured veining process for textured eco-stone of claim 1, wherein, A distribution device is arranged between the receiving belt and the flow belt, and between the flow belt and the distribution hopper; In step (3), when the color combination slurry passes through the distribution device, the color slurries of different colors in the color combination slurry are subjected to flow casting, dispersion and fusion.

4. The belt cast textured veining process for textured eco-stone of claim 3, wherein, The distribution device comprises a plurality of flow guides, and a distribution hole is formed between two adjacent flow guides.

5. The belt cast textured veining process for textured eco-stone of claim 1, wherein, The distribution hopper is provided with a moving mechanism; In step (3), while the color combination slurry is filled in the molds, the moving mechanism drives the distribution hopper to swing left and right perpendicular to the conveying direction of the molds, and the color combination slurry is filled in the molds through the distribution hopper to form a diagonal or wavy texture in the molds.

6. The belt cast textured veining process for textured eco-stone of claim 5, wherein, A plurality of partition strips are arranged in the distribution hopper, the partition strips divide the internal space of the distribution hopper into a plurality of small areas for discharging, and the color combination slurry flows out from the small areas after entering the distribution hopper.

7. The belt cast textured veining process for textured eco-stone of claim 1, wherein, After the slurry is prepared, the flowability of the slurry is tested, and the slurry is subjected to step (2) only when the flowability of the slurry is qualified, the flowability of the slurry is 60-70%, and the test method of the flowability of the slurry is as follows: The quantitative slurry is injected into an open container, weighed as W1, the weight of the open container is w, then the open container is turned over at 90°, and the slurry is poured out from the top opening of the open container; Timing is started at the same time when the open container is turned over, and after 30" of timing, the open container is turned back to the original position, and weighed as W2; The calculation formula of the flowability of the slurry is: [(W1-W2) / (W1-w)]x100%.

8. The belt cast textured veining process for textured eco-stone of claim 1, wherein, The raw materials of the slurry include, in parts by weight: white cement 25-30 parts, 26-40 mesh sand 10-20 parts, 40-70 mesh sand 20-30 parts, 70-120 mesh sand 10-20 parts, 100-200 mesh sand 5-10 parts, 300-500 mesh sand powder 5-10 parts, 1000-2000 mesh sand powder 5-10 parts, active kaolin 1-3 parts, active silica powder 3-5 parts, and water-based emulsion 1-3 parts; The raw materials of the slurry further include, based on the amount of white cement: whiskers 10-30 g / kg of white cement, alkali inhibitor 10-30 g / kg of white cement, defoaming agent 3-6 g / kg of white cement, water reducing agent 5-10 g / kg of white cement, rheological aid 3-6 g / kg of white cement; In the raw materials of the slurry, the sand-cement ratio is 2.0-3.

0.

9. The belt cast textured veining process for textured eco-stone of claim 8, wherein, The preparation method of the slurry is as follows: According to the formula amount, the white cement, active silica powder, active kaolin, whiskers, alkali inhibitor, defoaming agent, water reducing agent, color powder, rheological aid, and 26-40 mesh sand are mixed uniformly to obtain a premixed dry material; Water and water-based emulsion are added to the premixed dry material, stirred and slurried, then sand is added according to the formula amount, and stirred uniformly to obtain the slurry.

10. A textured eco-stone, characterized in that, The textured ecological stone is prepared by the belt flow texturing process of any one of claims 1-9.

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