A process for making a manufactured stone with a flow texture and articles thereof

Abstract

The application relates to the technical field of artificial stone products, in particular to an artificial stone manufacturing process with flowing texture and a product thereof, which comprises the following steps: S1, inner embryo preparation: preparing an inner embryo with a porous structure on an outer surface; S2, outer layer coating: uniformly coating a UHPC slurry layer on the outer surface of the inner embryo; S3, shaping and standing: preparing an outer mold to shape the intermediate part; and S4, taking out the finished product. The UHPC slurry mixed with at least two colors is coated on the outer surface of the inner embryo, the porous structure of the inner embryo is used to adsorb the slurry, natural and smooth hole stone flowing texture is formed, the three-layer structure of the outer mold can be matched with different shapes of artificial stone shaping requirements, the thickness of the UHPC outer layer is uniform, the qualified rate of the finished product is higher, the manufacturing process is simple and easy to operate, the outer surface is beautiful and has high economic value.

Description

Technical Field

[0001] This invention relates to the field of artificial stone products technology, and in particular to an artificial stone manufacturing process and products with flowing textures. Background Technology

[0002] Artificial stone is a decorative material synthesized using cement, resin, and other binders, mixed with natural gravel, pigments, and other artificial materials, designed to mimic the texture and feel of natural stone. It is widely used in indoor kitchen countertops, bathroom sinks, wall decorations, as well as outdoor landscaping, public building complexes, and custom-made irregularly shaped furniture. Currently, most artificial stone textures are achieved by directly pressing together different colorants, resulting in stiff, fixed textures that fail to replicate the naturally flowing textures of natural travertine. Furthermore, the production of large or irregularly shaped artificial stone products often results in inconsistent surface thickness and insufficient strength, making it difficult to meet the demands of the decoration industry for natural textures and personalized appearances. Summary of the Invention

[0003] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the description and other accompanying drawings.

[0004] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a process for manufacturing artificial stone with flowing textures and its products. By coating the outer surface of the inner substrate with a mixture of at least two colors of UHPC slurry, the porous structure of the inner substrate is used to absorb the slurry, forming a natural and smooth travertine flowing texture. Combined with the three-layer structure of the outer mold, it can adapt to the shaping needs of artificial stone of different shapes, ensure the uniform thickness of the outer UHPC layer, have a higher finished product qualification rate, and the manufacturing process is simple and easy to operate, with a beautiful appearance and high economic value. This invention provides a process for manufacturing artificial stone with flowing textures, comprising: S1. Endome preparation: Prepare an endome with a porous structure on its outer surface; S2, Outer Coating: A layer of UHPC slurry is uniformly coated on the outer surface of the inner body. The UHPC slurry is mixed with at least two colors to form an artificial stone intermediate with a flowing travertine texture. S3. Shaping and setting: Prepare an outer mold in advance. The outer mold is formed by splicing the left mold and the right mold. The middle part is placed between the left mold and the right mold. The outer mold has a three-layer structure and the inner shape is adapted to the outer shape of the middle part. It is used to shape the middle part located inside. Set it for a certain period of time until the outer UHPC slurry is completely dry. S4. Remove the finished product: Remove the outer mold to obtain an artificial stone product with a flowing texture on the outer layer.

[0005] In some embodiments, the inner substrate is made of foamed ceramic or foamed cement.

[0006] In some embodiments, the outer mold includes an outer layer, a middle layer, and an inner layer, the inner shape of which is adapted to the outer shape of the middle part, and the vertical distance between the inner surface of the inner layer and the outer surface of the inner blank is equal everywhere.

[0007] In some embodiments, the outer layer is a rigid material, the middle layer is a foamed sponge, and the inner layer is a breathable silicone.

[0008] In some embodiments, a thickener is added to the UHPC slurry, and the slump of the UHPC slurry is 170-210 mm.

[0009] An artificial stone product with a flowing texture is produced using an artificial stone manufacturing process that produces flowing textures.

[0010] By adopting the above technical solution, the beneficial effects of the present invention are: This invention involves coating the outer surface of the inner die with a mixture of at least two colors of UHPC slurry. The porous structure of the inner die absorbs the slurry, forming a natural and smooth travertine flow texture. Combined with the three-layer structure of the outer mold, it can adapt to the shaping needs of artificial stone of different shapes, ensuring uniform thickness of the UHPC outer layer, higher finished product qualification rate, simple and easy manufacturing process, beautiful appearance and high economic value.

[0011] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure.

[0012] Undoubtedly, such and other objects of the present invention will become more apparent after the following detailed description of the preferred embodiments, which are illustrated in various accompanying drawings and figures.

[0013] To make the above and other objects, features and advantages of the present invention more apparent and understandable, one or more preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0014] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0015] In the accompanying drawings, the same parts use the same reference numerals, and the drawings are schematic and not necessarily drawn to actual scale.

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one or more embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on such drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall manufacturing process in some embodiments of the present invention; Figure 2 This is a schematic diagram illustrating the interaction between the artificial stone product and the outer mold in some embodiments of the present invention; Figure 3 This is a schematic diagram of the flowing texture style in some embodiments of the present invention.

[0018] Explanation of key figure labels: 1. Inner layer; 2. UHPC slurry; 3. Outer layer; 4. Middle layer; 5. Inner layer. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0020] Furthermore, in the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and 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 this invention.

[0021] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral unit; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. However, specifying a direct connection indicates that the two main bodies are not connected through a transitional structure, but rather formed as a whole through a connecting structure. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0022] In this invention, unless otherwise expressly specified and limited, the first feature "on" or "below" the second feature may be in direct contact with the first and second features, or indirect contact through an intermediate medium. In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," 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, the 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.

[0023] Reference Figures 1-3 , Figure 1 This is a schematic diagram of the overall manufacturing process in some embodiments of the present invention; Figure 2 This is a schematic diagram illustrating the interaction between the artificial stone product and the outer mold in some embodiments of the present invention; Figure 3 This is a schematic diagram of the flowing texture style in some embodiments of the present invention.

[0024] According to some embodiments of the present invention, the present invention provides a process for manufacturing artificial stone with flowing textures, comprising: S1. Inner blank preparation: Prepare an inner blank 1, the outer surface of which has a porous structure; preferably, the inner blank 1 is made of foamed ceramic or foamed cement, or other materials with a porous structure distribution; lightweight materials are usually considered when making artificial stone. Foamed ceramic or foamed cement, in addition to being lightweight, has porous characteristics, which is conducive to the coating of UHPC slurry 2, so that UHPC slurry 2 can adhere tightly to the outer surface of the inner blank 1, avoiding delamination. At the same time, since UHPC slurry 2 has a certain fluidity, the gaps between the porous structures can slow down the falling speed of the slurry under the action of gravity, which is beneficial to the subsequent plasticization steps. It is understood that the specific shape of the inner blank 1 is not limited here, and any shape of inner blank 1 can be coated on the outside to make an artificial stone product.

[0025] S2, Outer coating: A layer of UHPC slurry 2 is uniformly coated on the outer surface of the inner body 1. The UHPC slurry 2 is formed by mixing at least two colors to create an artificial stone intermediate with a flowing travertine texture. A thickener is added to the UHPC slurry 2, and the slump of the UHPC slurry 2 is 170-210mm. UHPC boasts high strength, excellent durability, and superior plasticity and flowability, allowing for the creation of complex shapes and structures. Adding a thickener to UHPC slurry 2 effectively enhances its plastic viscosity. Simultaneously, UHPC slurry 2 with a slump between 170-210mm maintains adhesion to the object's surface while flowing slowly, preventing the coating from becoming thin at the top and thick at the bottom due to excessively rapid coating drop before step S3. For details on the flowing travertine texture formed by mixing at least two colors, please refer to... Figure 3 Flowing travertine textures can create a beautiful artificial stone effect while having high economic value. They are lightweight and have a certain ornamental value, especially the "fish belly white" marble texture, which has an even higher market value.

[0026] S3. Shaping and setting: Prepare an outer mold in advance. The outer mold is formed by splicing the left mold and the right mold. The middle part is placed between the left mold and the right mold. The outer mold has a three-layer structure and the inner shape is adapted to the outer shape of the middle part. It is used to shape the middle part located inside. Set it for a certain period of time until the outer UHPC slurry 2 is completely dry. Because UHPC slurry 2 has a certain fluidity, direct exposure and air drying can easily lead to a thin coating on top and a thick coating on the bottom, resulting in poor finished artificial stone. Therefore, an external mold is added. The left and right molds are spliced ​​together to place the semi-finished artificial stone in the middle, and the outer layer of UHPC slurry 2 is fixed and shaped. It can be understood that the outer mold may also include a bottom surface and a top surface (not shown in the figure), which are also used to shape the internal intermediate parts. It can be adapted to the specific shape of the inner blank 1 and the application scenario. The outer mold includes an outer layer 3, a middle layer 4 and an inner layer 5. The inner shape of the inner layer 5 is adapted to the outer shape of the middle part. The vertical distance between the inner surface of the inner layer 5 and the outer surface of the inner blank 1 is equal everywhere. The outer layer 3 is made of rigid material, the middle layer 4 is made of foamed sponge, and the inner layer 5 is made of breathable silicone. The outer mold, with its three-layer structure, is used to shape the UHPC slurry 2. The rigid outer layer 3 supports the mold and facilitates worker handling of the outer mold while shaping the interior. The foamed sponge in the middle layer connects the outer layer 3 and the inner layer 5. Its porous structure provides cushioning and facilitates bonding between the two layers. The flexible, breathable silicone in the inner layer 5 has high tensile strength, making it less prone to breakage or damage under tension. Its porous structure also provides excellent softness and elasticity, which is advantageous for creating molds with curved surfaces or requiring cushioning. It can eliminate voids between the UHPC material and the inner substrate 1. Flexible, breathable silicone is particularly suitable for the field of artificial stone with diverse shapes and support requirements. The vertical distance between the inner surface of the inner layer 5 and the outer surface of the inner substrate 1 is always equal, ensuring uniform thickness of the UHPC slurry 2 and guaranteeing the smoothness and gloss of the finished product surface.

[0027] S4. Remove the finished product: Remove the outer mold to obtain an artificial stone product with a flowing texture on the outer layer 3; the outer side of the artificial stone product has a flowing travertine texture.

[0028] The present invention also provides an artificial stone product with a flowing texture, which is made by an artificial stone manufacturing process with a flowing texture. The finished product includes an inner body 1 and a coating. The inner body 1 is made of foamed ceramic or foamed cement, and the coating is UHPC slurry 2.

[0029] It should be understood that the embodiments disclosed herein are not limited to the specific processing steps or materials disclosed herein, but should be extended to equivalent substitutions of such features as understood by those skilled in the art. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0030] The term "embodiment" in this specification refers to a specific feature or characteristic described in connection with an embodiment that is included in at least one embodiment of the invention. Therefore, phrases or "embodiments" appearing in various places throughout the specification do not necessarily refer to the same embodiment.

[0031] Furthermore, the described features or characteristics can be incorporated into one or more embodiments in any other suitable manner. In the above description, specific details, such as thickness, quantity, etc., are provided to provide a comprehensive understanding of embodiments of the invention. However, those skilled in the art will understand that the invention can be implemented without the aforementioned specific details or may be implemented using other methods, components, materials, etc.

Claims

1. A process for manufacturing artificial stone with flowing textures, characterized in that, include S1. Endome preparation: Prepare an endome with a porous structure on its outer surface; S2, Outer Coating: A layer of UHPC slurry is uniformly coated on the outer surface of the inner body. The UHPC slurry is mixed with at least two colors to form an artificial stone intermediate with a flowing travertine texture. S3. Shaping and setting: Prepare an outer mold in advance. The outer mold is formed by splicing the left mold and the right mold. The middle part is placed between the left mold and the right mold. The outer mold has a three-layer structure and the inner shape is adapted to the outer shape of the middle part. It is used to shape the middle part located inside. Set it for a certain period of time until the outer UHPC slurry is completely dry. S4. Remove the finished product: Remove the outer mold to obtain an artificial stone product with a flowing texture on the outer layer.

2. The manufacturing process of artificial stone with flowing texture according to claim 1, characterized in that, The inner body is made of foamed ceramic or foamed cement.

3. The manufacturing process of artificial stone with flowing texture according to claim 1, characterized in that, The outer mold includes an outer layer, a middle layer, and an inner layer. The inner shape of the inner layer is adapted to the outer shape of the middle part, and the vertical distance between the inner surface of the inner layer and the outer surface of the inner blank is equal everywhere.

4. The manufacturing process of artificial stone with flowing texture according to claim 3, characterized in that, The outer layer is made of rigid material, the middle layer is made of foamed sponge, and the inner layer is made of breathable silicone.

5. The manufacturing process of artificial stone with flowing texture according to claim 1, characterized in that, The UHPC slurry contains a thickener and has a slump of 170-210 mm.

6. An artificial stone product with a flowing texture, manufactured by any one of the artificial stone manufacturing processes with flowing textures according to claims 1-5.

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