A dry pressing ecological stone body texture cloth process and ecological stone

Abstract

The present application relates to the technical field of ecological stone, and particularly relates to a dry-pressing ecological stone body texture distribution process and ecological stone. The process adopts a dry distribution equipment; the process comprises the following steps: (1) preparing a plurality of different color powders; (2) distributing the powders of different colors into distribution hoppers at designated positions, the powders in the plurality of distribution hoppers of the distribution mechanism are discharged through discharge belts, and then fall into a collecting belt; the discharge proportions of the powders of different colors in the distribution hoppers are different, and the powders are dispersed into blocky materials of different sizes and irregular shapes; (3) forming a distribution texture material layer; (4) repeating step (3) to lay the blocky materials in a mold to a preset thickness; (5) after the material layer in the mold is flattened, the material layer is subjected to vibration pressing, and then is demolded to obtain a blank, and the blank is cured and polished to obtain the ecological stone with a body texture. The ecological stone is prepared by using the dry-pressing ecological stone body texture distribution process, and has the characteristics of a body texture of a natural stone.

Description

Technical Field

[0001] This invention relates to the field of eco-stone technology, and in particular to a dry-pressed eco-stone texture fabrication process and 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 mixing ingredients, molding, and curing. The application of materials is divided into two processes: dry application and wet application. The dry application process involves mixing various raw materials with water to create a sizable powder. Multiple colors of this powder are then filled into the mold cavity and pressed into shape using a press, enabling the application of simple patterns.

[0003] In existing technologies, the dry-laying process is used to achieve the patterned texture decorative effect of eco-stone. For example, current dry-laying methods involve dropping various colored powders onto a conveyor belt, which then transfers the powders into a mold, forming a multi-colored layer, which is then pressed into shape. While the resulting eco-stone has a uniform color and texture, it cannot achieve the multi-colored block decorative effect of natural stone. Currently, there are also dry-laying processes that involve inkjet printing on the powder layer before pressing, but these also fail to achieve the uniform multi-colored block decorative effect of natural stone. Summary of the Invention

[0004] The purpose of this invention is to propose a dry-pressed eco-stone textured fabric process, which uses irregular block materials to achieve the effect of textured color blocks throughout the body, and can achieve the effect of imitating natural stone throughout the body.

[0005] The purpose of this invention is to propose an eco-stone, which is prepared by a dry-pressed eco-stone textured fabric process, and has a good decorative effect due to its full-body texture.

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

[0007] A fabric process for creating a dry-pressed, textured ecological stone.

[0008] The process uses a dry material feeding device, which includes a mold conveyor belt and multiple material feeding mechanisms located above the mold conveyor belt. Each material feeding mechanism includes multiple material feeding hoppers, discharge belts, collection belts, collection hoppers, and briquetting belts arranged sequentially from top to bottom. Each material feeding hopper is equipped with a discharge belt, and the briquetting belt is equipped with a briquetting device. The discharge end of the briquetting belt is equipped with a spiral cutter and a material feeding toothed plate.

[0009] The process includes the following steps:

[0010] (1) Material preparation: Prepare powders of various colors;

[0011] (2) According to the product design requirements, different colored powders are delivered to the designated hoppers. The powders in the multiple hoppers of the fabric feeding mechanism are discharged through the discharge belt and fall to the collection belt. The discharge ratio of different colored hoppers is different. According to the design requirements, the collection belt transports powders of different colors and proportions to the collection hopper to form a textured mixture. The briquetting belt continuously transports the textured mixture to the briquetting device to press the textured mixture into blocks. The mixture is then cut into strips by a spiral cutter. The strips fall into the mold through the fabric toothed plate and disperse into blocks of different sizes and irregular shapes.

[0012] (3) Different fabric structures form blocks of different colors. As the blocks fall, the mold conveyor belt moves the mold, causing the blocks to be unevenly laid in the mold. Blocks of different colors are superimposed on each other in the mold to form a fabric texture layer.

[0013] (4) Repeat step (3) to lay the block material in the mold to a preset thickness;

[0014] (5) After the material layer in the mold is flattened, it is vibrated and pressed, and demolded to obtain a blank. After curing, solidification and polishing, the blank is used to obtain an ecological stone with a full-body texture.

[0015] Furthermore, the fabric toothed plate has a number of teeth of a preset shape and size.

[0016] Furthermore, a powder-spreading mechanism is provided after several of the aforementioned fabric-spreading mechanisms. The powder-spreading mechanism includes a screen, a screen fixing frame, and a vibrator. The screen and the vibrator are both mounted on the screen fixing frame.

[0017] The step (3) includes a powdering step: when the mold conveyor belt carries the mold past the powdering mechanism, the powdering mechanism causes the dry powder to be evenly spread on the surface of the block material layer through the screen, forming a fine line texture.

[0018] Furthermore, a spraying mechanism is provided corresponding to the powder-spreading mechanism, which is used to spray water or spray colored slurry;

[0019] In step (3), when the mold conveyor belt carries the mold past the spraying mechanism, the spraying mechanism sprays water or colored slurry onto the mold.

[0020] Furthermore, the dry fabric making equipment also includes a large texture pressing and breaking mechanism, which is located between two adjacent fabric making mechanisms. The large texture pressing and breaking mechanism has a plurality of pressing and breaking blades arranged in an alternating manner, and the plurality of pressing and breaking blades are flat.

[0021] In step (3), when the mold passes through the large texture breaking mechanism, several breaking blades press into the material layer inside the mold, and the depth of the breaking blades pressing into the material layer is less than or equal to the thickness of the material layer.

[0022] Furthermore, the side and front end of the mold conveyor belt are connected to a recycling belt, which is used to transport the recycled material to the grinder, the grinder breaks up the recycled material, and the broken recycled powder is transported to the return material replenishment mechanism.

[0023] Between steps (4) and (5), there is a material return and powder replenishment step: after the material layer of the mold is stacked to a preset thickness through multiple material feeding stations, it is transported by the mold conveyor belt to the bottom of the material return and powder replenishment mechanism, and the material return and powder replenishment mechanism will recycle the powder to fill the material layer in the mold.

[0024] Furthermore, in step (2), a material distribution system distributes various powders of different colors into the fabric hopper;

[0025] The material delivery system includes several material delivery conveyor lines and several powder dispersing lines. Each material delivery conveyor line has a transfer hopper, which moves along the material delivery conveyor line.

[0026] The material delivery conveyor line has at least one loading station and several unloading stations; the discharge end of the powder dispersing line is located above the loading station, and the material hopper is located below the unloading station; the transfer material hopper receives the powder transported from the discharge end of the powder dispersing line at the loading station and transfers the powder to the material hopper.

[0027] In step (2), one of the transfer cloth hoppers receives the powder transported out by the powder dispersing line and transfers the powder to a cloth hopper so that each cloth hopper holds a powder of one color.

[0028] Furthermore, the raw materials of the powder, by weight, include:

[0029] 22-26 parts white cement, 20-40 parts 40-70 mesh sand, 20-40 parts 70-120 mesh sand, 3-5 parts 325 mesh sand powder, 1-3 parts activated kaolin, 1-3 parts activated silica powder, and 1-3 parts water-based emulsion.

[0030] Based on the amount of white cement used, the raw materials for the slurry also include:

[0031] Whiskers 10-30 g / kg white cement, alkali inhibitor 10-30 g / kg white cement, water reducer 5-10 g / kg white cement, moisture-retaining agent 1-5 g / kg white cement.

[0032] Furthermore, in step (1), the method for preparing materials is as follows:

[0033] First, mix the white cement, sand powder, whiskers, defoamer, water-reducing agent and rheology modifier evenly according to the formula to obtain the premix;

[0034] Then, water is added to the premix and stirred to form a slurry;

[0035] Finally, add sand according to the formula and stir evenly to obtain the powder.

[0036] An eco-stone with a full-body texture is prepared using the aforementioned dry-pressed eco-stone full-body texture fabric process.

[0037] The technical solution provided by this invention may include the following beneficial effects:

[0038] 1. In the process of this invention, irregular block-shaped materials are used to achieve the effect of a full-body texture;

[0039] 2. A recycling belt is used to collect the fallen powder in real time and promptly transport it to a grinding mill for crushing and to a powder return and replenishment mechanism for reuse. This achieves real-time collection and reuse of the fallen powder, saving labor, ensuring the cleanliness of the reused powder, and preventing the fallen powder from becoming too dry and difficult to crush. This invention creatively uses the reused powder in the final powder spreading step of the dry-process fabric application, which not only achieves the timely use of the reused powder but also improves the simulation effect of the eco-stone.

[0040] 3. A feeding system distributes various powders of different colors into the cloth hoppers. The feeding system can distribute a few types of powders into multiple cloth hoppers in each cloth feeding mechanism. Furthermore, each cloth feeding mechanism's multiple hoppers can hold powders of different colors, and the color combinations of powders in each cloth feeding mechanism can also be different, thus diversifying the color combination methods of each cloth feeding mechanism. This, in turn, diversifies the color combination methods of the block material, thereby diversifying the decorative effects of the eco-stone. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of a dry fabric spreading device according to an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram showing the coordination between the material feeding system and the fabric hopper of a dry fabric laying equipment;

[0043] Figure 3This is a schematic diagram showing the coordination of the mold conveyor belt, recycling belt, grinding mill, and return powder replenishment mechanism in a dry fabric processing equipment.

[0044] Figure 4 This is a schematic diagram of the fabric toothed plate;

[0045] Among them, the mold conveyor belt 1, mold 11, material feeding mechanism 01, spraying mechanism 02, pressing belt 011, collecting belt 012, material feeding hopper 013, material feeding toothed plate 014, tooth 015, spiral cutter 016; large texture pressing mechanism 4, powder spreading mechanism 5, recycling belt 6, grinding machine 7, return material replenishing powder mechanism 8, material dispensing system 9, material dispensing conveyor line 91, powder dispersing line 92, and transfer material feeding hopper 93. Detailed Implementation

[0046] 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.

[0047] In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "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.

[0048] In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0049] 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.

[0050] Reference Figure 1-4This invention provides a dry-pressed eco-stone textured fabric application process. The process uses a dry fabric application device, which includes a mold conveyor belt 1 and multiple fabric application mechanisms located above the mold conveyor belt 1. Each fabric application mechanism includes multiple fabric application hoppers 013, a collection hopper, a pressing belt 011, and a collection belt 012 arranged sequentially from top to bottom. Each fabric application hopper 013 corresponds to a discharge belt. The pressing belt 011 is correspondingly provided with a pressing plate. The discharge end of the pressing belt 011 is provided with a spiral cutter and a fabric application toothed plate 014.

[0051] The process includes the following steps:

[0052] (1) Material preparation: Prepare powders of various colors;

[0053] (2) According to the product design requirements, different colored powders are delivered to the designated hopper 013. The powders in the multiple hoppers 013 of the fabric feeding mechanism 01 are discharged through the discharge belt and fall to the collection belt 012. The discharge ratio of different colored hoppers is different. According to the design requirements, the collection belt 012 conveys powders of different colors and proportions to the collection hopper to form textured mixtures. The briquetting belt 011 continuously conveys the textured mixtures to the briquetting device, presses the textured mixtures into blocks, and cuts them into strips by the spiral cutter. The strips fall into the mold through the fabric toothed plate and are dispersed into blocks of different sizes and irregular shapes.

[0054] (3) Different fabric structures form blocks of different colors. As the blocks fall, the mold conveyor belt moves the mold, causing the blocks to be unevenly laid in the mold. Blocks of different colors are superimposed on each other in the mold to form a fabric texture layer.

[0055] (4) Repeat step (3) to lay the block material in the mold 11 to a preset thickness;

[0056] (5) After the material layer in the mold 11 is flattened, it is vibrated and pressed, and demolded to obtain a blank. After curing, solidification and polishing, the blank is used to obtain an ecological stone with a full-body texture.

[0057] To address the problem that existing dry-pressed fabrics cannot achieve a full-body textured eco-stone, this invention provides a dry-pressed eco-stone full-body texture fabrication process, which uses irregular block-shaped materials to achieve the effect of full-body textured color blocks.

[0058] First, each cloth-laying mechanism contains powder of various colors. These powders are spread and mixed to some extent on the collecting belt 012, resulting in pressed blocks with diverse color combinations and irregularly shaped areas. As the blocks pass through the cloth-laying toothed plate 014, they are cut and dispersed into smaller blocks by gravity. These blocks fall randomly into the mold 11, and may be further broken into smaller, irregular particles as they fall. Multiple cloth-laying mechanisms sequentially fill the mold 11, layering the blocks to create a textured effect reminiscent of natural stone. Furthermore, the irregular shapes and sizes of the blocks, along with their color combinations, result in different shapes, color combinations, and sizes of color blocks within each layer, achieving an effect similar to granite or marble. It is understandable that when the block material is laid in the mold 11, the block material is in an inclined or horizontal state, and the multi-layer block material has an overlapping effect. Moreover, the cut surface of the ecological stone can still show color patches, and the ecological stone has a better simulation effect.

[0059] Furthermore, the conveying speed of the collecting belt 012 affects the thickness of the material layer on the briquetting belt 011, and the conveying speed of the briquetting belt 011 affects the feeding speed and shape of the lumps. The conveying speed of the mold conveyor belt 1 affects the laying density of the lumps in the mold 11. Therefore, by adjusting the conveying speeds of the collecting belt 012, the briquetting belt 011, and the mold conveyor belt 1, the feeding quantity and density can be adjusted.

[0060] In some embodiments of the present invention, a vacuum-vibration pressing method is used to form the powder in the mold 11. The steps are as follows: maintaining continuous vacuum, the press first pounds and compacts the powder in the mold 11 at a low frequency, and then pounds and compacts the powder in the mold 11 at a high frequency. This pressing method can ensure that the air in the powder can be fully expelled, ensuring the density of the ecological stone structure.

[0061] Furthermore, the fabric toothed plate 014 has a number of teeth of a preset shape and size.

[0062] Understandably, on the pressing belt 011, the pressing plate exerts relatively low pressure on the powder, only enough to form the powder into lumps and maintain a certain shape during its descent. Therefore, based on the cutting effect of the spiral cutter 016 and the dispersing effect of the fabric toothed plate 014, the lumps can be dispersed into irregular lumps. Moreover, due to the diversity of the teeth 015 of the fabric toothed plate 014, the shape and size of the lumps are more diverse, which is beneficial to improving the simulation effect of the eco-stone.

[0063] Specifically, in this technical solution, each tooth 015 on the fabric toothed plate 014 is different in size and shape. Some teeth 015 are longer, some are shorter, some are wider, and some are narrower. This allows the cut strips of powder to be irregularly dispersed, forming blocks of varying sizes and shapes. These blocks are then irregularly dispersed in the mold 11, thereby enhancing the randomness and irregularity of the pattern in the product and making the overall effect more natural.

[0064] Furthermore, a powder-spreading mechanism 5 is provided after several fabric-spreading mechanisms. The powder-spreading mechanism 5 includes a screen, a screen fixing frame, and a vibrator. The screen and the vibrator are both installed on the screen fixing frame.

[0065] The step (3) includes a powdering step: when the mold conveyor belt 1 carries the mold 11 past the powdering mechanism, the powdering mechanism causes the dry powder to be evenly spread on the surface of the block material layer through the screen, forming a fine line texture.

[0066] In some technical solutions of the present invention, step (3) includes a powder-sprinkling step. The dry powder sprinkled by the powder-sprinkling mechanism 5 falls into the mold 11. Due to the uneven surface of the material layer inside the mold 11, some blocky materials are in an inclined state, causing the powder to slide off the surface of the material layer and accumulate at the edges of some blocky materials, forming a wrapping texture. This simulates the color accumulation at the edges of large color spots in natural stone, further improving the simulation effect. In one embodiment, the powder in the powder-sprinkling mechanism has a basically the same formula as the powder in the self-laying mechanism, the difference being the type of colorant.

[0067] Furthermore, a spraying mechanism 02 is provided corresponding to the powder-spreading mechanism, the spraying mechanism 02 being used to spray water or spray colored slurry;

[0068] In step (3), when the mold conveyor belt 1 carries the mold 11 past the spraying mechanism 02, the spraying mechanism 02 sprays water or colored slurry onto the mold 11.

[0069] In some embodiments of the present invention, a spraying mechanism 02 is provided, and one or more fabric feeding mechanisms 01 are correspondingly provided with a spraying mechanism 02 at their discharge ends. The spraying mechanism 02 is used to spray water or colored slurry. When the spraying mechanism 02 sprays water, it can increase the adhesion between the various layers in the mold 11. When the spraying mechanism 02 sprays colored slurry, it can not only increase the adhesion between the various layers in the mold 11, but also enhance the decorative effect of the surface of the eco-stone.

[0070] Furthermore, the dry fabric making equipment also includes a large texture pressing and breaking mechanism, which is located between two adjacent fabric making mechanisms. The large texture pressing and breaking mechanism 4 has a plurality of pressing and breaking blades arranged in an alternating manner, and the plurality of pressing and breaking blades are flat.

[0071] In step (3), when the mold 11 passes through the large texture breaking mechanism 4, several breaking blades press into the material layer inside the mold 11, and the depth of the breaking blades pressing into the material layer is less than or equal to the thickness of the material layer.

[0072] In one embodiment of the present invention, the dry fabric laying equipment has a large texture breaking mechanism 4, which forms a fracture in the material layer, that is, breaks the block material to form a groove-like texture. The subsequent fabric laying covers the groove-like texture, and finally the ecological stone forms a texture similar to root patterns, further improving the simulation effect of the ecological stone.

[0073] Understandably, the cracks in natural stone are usually straight. Therefore, the cutting blade in the large texture cutting mechanism 4 of this invention is flat to form straight cracks. The cracks need to penetrate into the ecological stone to a certain depth so that the top and cross-section of the ecological stone can achieve a better simulation effect. Therefore, in this invention, the depth of the cutting blade into the material layer is less than or equal to the thickness of the material layer.

[0074] Furthermore, the side and front end of the mold conveyor belt 1 are connected to a recycling belt 6, which is used to transport the recycled material to the grinder 7. The grinder 7 will break up the recycled material, and the broken recycled powder will be transported to the return material replenishment mechanism 8.

[0075] Between steps (4) and (5), there is a material return and powder replenishment step: after the material layer of the mold 11 is stacked to a preset thickness through multiple material feeding stations, it is transported by the mold conveyor belt to the bottom of the material return and powder replenishment mechanism 8, and the material return and powder replenishment mechanism 8 fills the material layer in the mold 11 with recycled powder.

[0076] In the dry-laying process of forming eco-stone, a material-laying device is typically used to spread the powder into a mold 11. The mold 11 moves below the material-laying device, driven by a mold conveyor belt 1. During this process, powder inevitably spills onto the conveyor surface of the mold conveyor belt 1 and falls to the ground, wasting powder and polluting the production environment. In existing technologies, powder recycling involves manually collecting the powder from the ground and then crushing and reusing it after a certain amount is collected. However, due to the long storage time of the powder, the moisture has completely evaporated and some cement has solidified, making crushing difficult. Furthermore, the collection process often involves collecting dust from the ground, causing powder pollution and requiring a large amount of manual labor.

[0077] In this invention, a recycling belt 6 collects the fallen powder in real time and promptly conveys it to a grinding mill 7 for crushing and to a return powder replenishment mechanism 8 for reuse. This achieves real-time collection and reuse of the fallen powder, saving labor, ensuring the cleanliness of the reused powder, and preventing the fallen powder from becoming too dry and difficult to crush. This invention creatively uses the reused powder in the final powder-spreading step of dry-laying materials, achieving not only timely use of the reused powder but also improving the simulation effect of the eco-stone.

[0078] Specifically, the recycled powder is a mixture of more colored powders, and the colors are different from the powders in each fabric mechanism 01. The recycled powder is sprinkled into the mold 11. Due to the uneven surface of the material layer in the mold 11, some block materials are in an inclined state. The recycled powder fills the gaps between the block materials.

[0079] Furthermore, in step (2), the material distribution system 9 distributes various powders of different colors to the fabric hopper 013;

[0080] The material delivery system 9 includes several material delivery conveyor lines 91 and several powder dispersing lines 92. Each material delivery conveyor line 91 has a transfer hopper 93, which moves along the material delivery conveyor line 91.

[0081] The material delivery conveyor line 91 has at least one loading station and several unloading stations; the discharge end of the powder dispersing line 92 is located above the loading station, and the material distribution hopper 013 is located below the unloading station; the transfer material distribution hopper 93 receives the powder transported from the discharge end of the powder dispersing line 92 at the loading station and transfers the powder to the material distribution hopper 013.

[0082] In step (2), a transfer hopper 93 receives powder transported by a powder dispersing line 92 and transfers the powder to a hopper 013 so that each hopper 013 holds a powder of one color.

[0083] In one embodiment of the present invention, a feeding system 9 distributes various powders of different colors into the fabric hoppers 013. The feeding system 9 can distribute a small number of types of powders into multiple fabric hoppers 013 of each fabric fabrication mechanism 01.

[0084] For example, when there are four powder dispersing lines 92 and three feeding conveyor lines 91, each powder dispersing line 92 conveys one color of powder, and each feeding conveyor line 91 has one transfer hopper 93. Two of the three feeding conveyor lines 91 each have only one loading station, and one has two loading stations. The inlet of each feeding hopper 013 covers all three feeding lines, so each feeding line has a corresponding unloading station for each feeding hopper 013. On one feeding conveyor line 91, the transfer hopper receives powder at the loading station and then moves along the feeding conveyor line 91 to an unloading station, transferring the powder to the corresponding feeding hopper 013. Therefore, on one feeding line, the transfer hopper 93 can transport the received powder to any feeding hopper 013, and any feeding hopper 013 can receive powder transported from all three feeding lines.

[0085] Therefore, it can be seen that by using the aforementioned material distribution system 9, a few types of powder can be distributed to multiple feeding hoppers 013 of each feeding mechanism 01, and the multiple feeding hoppers 013 of each feeding mechanism 01 can hold powder of different colors. The color combinations of powder in each feeding mechanism 01 can also be different, thus diversifying the color combination methods of each feeding mechanism 01, which in turn diversifies the color combination methods of block materials, and consequently, diversifies the decorative effects of eco-stone. It is understandable that the powder is a semi-dry material, and clumping may occur during the transportation process. The powder dispersing line 92 disperses the powder and transfers it to the transfer feeding hopper.

[0086] Furthermore, the raw materials of the powder, by weight, include:

[0087] 22-26 parts white cement, 20-40 parts 40-70 mesh sand, 20-40 parts 70-120 mesh sand, 3-5 parts 325 mesh sand powder, 1-3 parts activated kaolin, 1-3 parts activated silica powder, and 1-3 parts water-based emulsion.

[0088] Based on the amount of white cement used, the raw materials for the slurry also include:

[0089] Whiskers 10-30 g / kg white cement, alkali inhibitor 10-30 g / kg white cement, water reducer 5-10 g / kg white cement, moisture-retaining agent 1-5 g / kg white cement.

[0090] In this invention, the powder material uses white cement as the main component, with added whiskers, sand, and sand powder to increase the strength of the eco-stone. Activated kaolin, activated silica powder, and water-based emulsion facilitate the molding of the powder during pressing. A moisturizing agent is used to improve the water retention of the powder, preventing it from drying and clumping during the spreading process, and ensuring that the spreading mechanism 01 can press the powder into blocks. For example, hydroxypropyl methylcellulose is used as the moisturizing agent. In this solution, the sand 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 powder also include colorants; different colorants yield powders of different colors. If no colorants are added, the resulting powder is white.

[0091] Furthermore, in step (1), the method for preparing materials is as follows:

[0092] First, mix the white cement, sand powder, whiskers, defoamer, water-reducing agent and rheology modifier evenly according to the formula to obtain the premix;

[0093] Then, water is added to the premix and stirred to form a slurry;

[0094] Finally, add sand according to the formula and stir evenly to obtain the powder.

[0095] 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.

[0096] Accordingly, the present invention also provides an eco-stone with a continuous texture, which is prepared using the aforementioned dry-pressed eco-stone continuous texture fabric process. This eco-stone with a continuous texture has the effect of imitating marble or granite, with good simulation effect and the characteristic of continuous texture.

[0097] The present invention is further illustrated below through examples.

[0098] Example Group 1: Fabrication process for dry-pressed eco-stone with full-body texture

[0099] Example 1-1

[0100] The process uses a dry material feeding device, which includes a mold conveyor belt 1 and a material feeding mechanism located above the mold conveyor belt 1. The material feeding mechanism includes a pressing belt 011, a collecting belt 012 and multiple material feeding hoppers 013 arranged sequentially from bottom to top. The pressing belt 011 is equipped with a pressing plate, and the discharge end of the pressing belt 011 has a material feeding toothed plate 014.

[0101] The process includes the following steps:

[0102] Step (1) Material preparation: Prepare powders of different colors.

[0103] In step (2): the material distribution system 9 distributes various powders of different colors to the cloth hopper 013;

[0104] The material distribution system 9 includes several material distribution conveyor lines 91 and several powder dispersing lines 92. Each material distribution conveyor line 91 has a transfer hopper 93, which moves along the material distribution conveyor line 91.

[0105] The material conveying line 91 has at least one loading station and several unloading stations; the discharge end of a powder dispersing line 92 is located above a loading station, and a material distribution hopper 013 is located below an unloading station; the transfer material distribution hopper 93 receives the powder transported from the discharge end of the powder dispersing line 92 at a loading station and transfers the powder to a material distribution hopper 013.

[0106] A transfer hopper 93 receives powder transported from a powder dispersing line 92 and transfers the powder to a hopper 013 so that each hopper 013 holds a powder of one color.

[0107] The powder in the multiple feeding hoppers 013 of the feeding mechanism 01 falls to the collecting belt 012, which conveys the powder to the briquetting belt 011. The pressing plate presses the powder on the briquetting belt 011 into lumps. After passing through the feeding toothed plate 014, the lumps are dispersed into lumps of different sizes and irregular shapes.

[0108] Specifically, the fabric toothed plate 014 has several teeth 015 connected in sequence on the side opposite to the pressure belt. The teeth 015 are of different sizes and shapes. There is a smooth transition between two adjacent teeth 015. The spacing between the tips of adjacent teeth 015 is different. The tips of the teeth 015 are rounded or pointed. A spiral cutter 016 is provided at the fabric toothed plate 014. The spiral cutter 016 rotates and cuts the block material on the pressure belt 011 into strips. After the strips of block material pass through the fabric toothed plate 014, they are dispersed into blocks of different sizes and irregular shapes.

[0109] According to the product design requirements, powders of different colors are delivered to the designated hoppers. The powders in the multiple hoppers of the fabric feeding mechanism are discharged through the discharge belt and fall to the collection belt. The discharge ratio of different colored hoppers is different. According to the design requirements, the collection belt transports powders of different colors and proportions to the collection hopper to form a textured mixture. The briquetting belt continuously transports the textured mixture to the briquetting device, which presses the textured mixture into blocks. The blocks are then cut into strips by a spiral cutter. The strips fall into the mold through the fabric toothed plate and disperse into blocks of different sizes and irregular shapes.

[0110] (3) Different fabric structures form blocks of different colors. As the blocks fall, the mold conveyor belt moves the mold, causing the blocks to be unevenly laid in the mold. Blocks of different colors are superimposed on each other in the mold to form a fabric texture layer.

[0111] (4) Repeat step (3) to lay the block material in the mold to a preset thickness;

[0112] (5) After the material layer in the mold is flattened, it is vibrated and pressed, and demolded to obtain a blank. After curing, solidification and polishing, the blank is used to obtain an ecological stone with a full-body texture.

[0113] Between steps (4) and (5) of this process, there is also a material return and powder replenishment step: the side of the mold conveyor belt 1 and the front end of the conveyor have a connected recycling belt 6, which is used to transport the recycled material to the grinder 7. The grinder 7 will break up the recycled material, and the broken recycled powder will be transported to the material return and powder replenishment mechanism 8.

[0114] After the material layers of the mold 11 are stacked to a preset thickness through multiple material feeding stations, it is transported by the mold conveyor belt to the bottom of the material return and powder replenishment mechanism 8. The material return and powder replenishment mechanism 8 will fill the material layer in the mold 11 with recycled powder.

[0115] Examples 1-2

[0116] This embodiment is basically the same as the process of embodiment 1-1, except that a powder spreading mechanism 5 is provided after several of the cloth spreading mechanisms. The powder spreading mechanism 5 includes a screen, a screen fixing frame and a vibrator. The screen and the vibrator are both installed on the screen fixing frame.

[0117] Step (3) includes a powdering step: when the mold conveyor belt 1 carries the mold 11 past the powdering mechanism, the powdering mechanism makes the dry powder pass through the screen and evenly spread a layer of dry powder on the surface of the block material layer to form fine line texture.

[0118] Correspondingly, a spraying mechanism 02 is provided in conjunction with the powder spreading mechanism. The spraying mechanism 02 is used to spray water or spray colored slurry.

[0119] In step (3) and / or step (7), when the mold conveyor belt 1 carries the mold 11 past the spraying mechanism 02, the spraying mechanism 02 sprays water or colored slurry onto the mold 11.

[0120] Example Group 2: Ecological Stone with Full-Body Texture

[0121] The formula for the textured eco-stone of this embodiment is shown in the table below.

[0122]

[0123] The formulations of Examples 2-1 to 2-5 above were prepared into powder using the following method:

[0124] First, mix the white cement, sand powder, whiskers, defoamer, water-reducing agent and rheology modifier evenly according to the formula to obtain the premix;

[0125] Then, water is added to the premix and stirred to form a slurry;

[0126] Finally, add sand according to the formula and stir evenly to obtain the powder.

[0127] Applying the above-mentioned slurry to Example Group 1 yields eco-stones with various decorative effects. Testing showed that all indicators of the eco-stones met industry standards.

[0128] The fabrication process for dry-pressed eco-stone with a full-body texture according to an embodiment of the present invention, as well as other components of the eco-stone and the operation thereof, are known to those skilled in the art and will not be described in detail here.

[0129] 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.

[0130] 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 process for dry pressing an ecological stone body texture cloth, characterized in that, The process adopts a dry material distribution device, which comprises a mold conveying belt and a plurality of material distribution mechanisms above the mold conveying belt, each of the material distribution mechanisms comprises a plurality of material hoppers, a material collecting belt, a material collecting hopper and a briquetting belt arranged in sequence from top to bottom, each material hopper is provided with a discharging belt, the briquetting belt is provided with a briquetting device, and the discharging end of the briquetting belt is provided with a spiral cutter and a material distribution toothed plate; The process comprises the following steps: (1) preparing a plurality of different color powders; (2) distributing the powders of different colors to the designated material hoppers according to the product design requirements, the powders in the material hoppers of the material distribution mechanisms are discharged through the discharging belts and fall onto the material collecting belt, the discharging proportions of the powders in the material hoppers of different colors are different, the material collecting belt conveys the powders of different colors and different proportions to the material collecting hopper to form a texture mixed material, the briquetting belt continuously conveys the texture mixed material to the briquetting device to press the texture mixed material into blocks, the blocks are divided into strips by the spiral cutter, and the strips fall onto the mold through the material distribution toothed plate and are dispersed into blocks of different sizes and irregular shapes; (3) the material distribution mechanisms form blocks of different colors, the mold conveying belt moves while carrying the mold so that the blocks are unevenly laid in the mold, and the blocks of different colors are stacked in the mold to form a material layer with a texture; (4) repeating step (3) to lay the blocks in the mold to a preset thickness; (5) after the material layer in the mold is flattened, vibration pressing is performed to obtain a blank, and the blank is cured, polished and then an ecological stone with a texture is obtained; The side part and the conveying front end of the mold conveying belt are provided with a recovery belt in connection, the recovery belt is used for conveying the recovered material to a grinding machine, the grinding machine disperses the recovered material, and the dispersed recovered powder is conveyed to a material recovery and supplementing mechanism; Between step (4) and step (5), there is also a material recovery and supplementing step: after the material layer in the mold is stacked to a preset thickness by a plurality of material distribution stations, the mold is conveyed to the lower side of the material recovery and supplementing mechanism by the mold conveying belt, and the material recovery and supplementing mechanism fills the material layer in the mold with recovered powder.

2. The process of claim 1, wherein the texture of the fabric is a random pattern. The material distribution toothed plate has a plurality of teeth with a preset shape and size.

3. The dry pressing of an ecological stone bulk texture cloth process according to claim 1, characterized in that, A powder scattering mechanism is arranged behind the plurality of material distribution mechanisms, the powder scattering mechanism comprises a screen, a screen fixing frame and a vibrator, and the screen and the vibrator are both mounted on the screen fixing frame; In step (3), there is a powder scattering step: when the mold conveying belt carrying the mold passes below the powder scattering mechanism, the powder scattering mechanism uniformly spreads a layer of dry powder on the surface of the block layer through the screen to form a fine line texture.

4. The process of claim 3, wherein the process further comprises, A spraying mechanism is arranged corresponding to the powder scattering mechanism, and the spraying mechanism is used for spraying water or colored paste; In step (3), when the mold conveying belt carrying the mold passes below the spraying mechanism, the spraying mechanism sprays water or colored paste to the mold.

5. The dry pressing of an ecological stone bulk texture cloth process according to claim 1, characterized in that, The dry material distributing device further comprises a large-texture breaking mechanism, which is located between two adjacent material distributing mechanisms and has a plurality of breaking blades arranged in staggered manner, wherein the breaking blades are flat plates; In the step (3), when the mold passes through the large-texture breaking mechanism, the breaking blades are pressed into the material layer in the mold, and the depth of the breaking blades pressed into the material layer is less than or equal to the thickness of the material layer.

6. The dry pressing ecostone bulk texture laying process according to claim 1, wherein, In the step (2), the color-different powder materials are distributed to the material distributing hoppers by a distribution feeding system. The distribution feeding system comprises a plurality of distribution feeding conveying lines and a plurality of powder scattering lines, each of the distribution feeding conveying lines has a transfer material distributing hopper, and the transfer material distributing hopper moves along the distribution feeding conveying line. Each of the distribution feeding conveying lines has at least one loading station and a plurality of unloading stations, the discharge end of one of the powder scattering lines is located above the loading station, and one of the material distributing hoppers is located below the unloading station; the transfer material distributing hopper receives the powder discharged from the discharge end of one of the powder scattering lines at the loading station and transfers the powder to one of the material distributing hoppers. In the step (2), one of the transfer material distributing hoppers receives the powder discharged from one of the powder scattering lines and transfers the powder to one of the material distributing hoppers, so that each of the material distributing hoppers contains one color of powder.

7. The dry pressing of an ecological stone bulk texture cloth process according to claim 1, characterized in that, The raw materials of the powder include, by weight: 22-26 parts of white cement, 20-40 parts of 40-70 mesh sand, 20-40 parts of 70-120 mesh sand, 3-5 parts of 325 mesh sand powder, 1-3 parts of active kaolin, 1-3 parts of active silica powder, and 1-3 parts of water-based emulsion; Based on the amount of white cement, the raw materials of the powder further include: 10-30 grams per kilogram of white cement of whiskers, 10-30 grams per kilogram of white cement of alkali inhibitor, 5-10 grams per kilogram of white cement of water reducing agent, and 1-5 grams per kilogram of white cement of moisture retention aid.

8. The process of claim 7, wherein the process further comprises, In the step (1), the method for preparing the raw materials is as follows: First, the white cement, sand powder, whiskers, defoaming agent, water reducing agent, and rheological aid are mixed according to the formula amount to obtain a premix; Then, water is added to the premix and stirred to form a slurry; Finally, the sand is added according to the formula amount, and the mixture is stirred to obtain the powder.

9. An ecological stone with a body texture, characterized in that, The powder is prepared by the dry pressing ecological stone body texture distributing process according to any one of claims 1-8.

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