Surface finishing methods for stone panels

Abstract

To provide a surface finishing method for stone panels that allows for a richer color finish while retaining the texture of a rough surface finish. [Solution] A method for surface finishing stone panels, comprising a stone panel forming step (S1) of cutting pre-cut raw stone to form stone panels of a predetermined thickness, and a water jet finishing step (S3) of roughening the surface of the formed stone panels by spraying a liquid pressurized by a high-pressure pump from a nozzle, wherein the roughening in the water jet finishing step is performed with a nozzle spray pressure of 1200 kg / cm². 2 More than 2400kg / cm 2 This is done by injecting ultra-high-pressure liquid as set below.

Description

[Technical Field]

[0001] This disclosure relates to a method for surface finishing stone panels. [Background technology]

[0002] Conventionally, stone panels used as surface materials for buildings and the like are formed by cutting raw stone to a predetermined thickness. The surface of the stone panel is then washed with water and given a rough finish. One known finishing method for roughening the surface of a stone panel is to heat the surface layer with a high-temperature jet flame (see, for example, Patent Document 1).

[0003] Furthermore, a surface finishing method using a water jet is known, which involves roughening the surface of stone panels by spraying high-pressure water pressurized by a high-pressure pump. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-open No. 60-129213 [Overview of the project] [Problems that the invention aims to solve]

[0005] Incidentally, a smooth, mirror-like polished surface of a stone panel can suppress diffuse reflection and achieve a deeper color. However, polishing a stone panel results in a glossy surface, giving it a different texture from a rough finish. On the other hand, conventional rough finishes using jet flames or water jets cannot sufficiently suppress diffuse reflection on the surface of the stone panel, making it difficult to achieve a deep color.

[0006] This disclosure addresses the above-mentioned issues and aims to provide a surface finishing method for stone panels that allows for a richer color finish while retaining the texture of a rough surface finish on the surface of the stone panel. [Means for solving the problem]

[0007] To achieve the above objective, the present disclosure provides a surface finishing method for stone panels, comprising: a stone panel forming step of cutting pre-cut raw stone to form a stone panel of a predetermined thickness; and a water jet finishing step of roughening the surface of the formed stone panel by spraying a liquid pressurized by a high-pressure pump from a nozzle, wherein the roughening in the water jet finishing step is performed with a nozzle spray pressure of 1200 kg / cm². 2 More than 2400kg / cm 2 This is characterized by being performed by the injection of ultra-high pressure liquid as set below. [Effects of the Invention]

[0008] The surface finishing method for stone panels described herein allows for a darker color finish while retaining the texture of a rough surface finish on the surface of the stone panel. [Brief explanation of the drawing]

[0009] [Figure 1] This is an external perspective view showing the stone panel of this embodiment. [Figure 2] This is a schematic diagram showing a surface finishing apparatus used in the surface finishing method for stone panels according to this embodiment. [Figure 3A] This is a schematic perspective view showing the nozzle of a surface finishing device. [Figure 3B] This is a plan view showing the nozzle's spray opening. [Figure 4] This is a flowchart showing the manufacturing procedure for the stone panel of this embodiment. [Figure 5A] This is a schematic cross-sectional view of the surface of a stone panel after roughening by spraying high-pressure water with a nozzle spray pressure set to 500 kg / cm² or higher and 600 kg / cm² or lower. [Figure 5B] This is a schematic cross-sectional view of the surface of the stone panel after polishing. [Figure 5C] This is a schematic cross-sectional view of the surface of the stone panel after rough finishing by the surface finishing method of the stone panel of this embodiment. [Figure 6A] This is an enlarged view of the surface of the stone panel after rough finishing by the surface finishing method of the stone panel of this embodiment. [Figure 6B] This is an enlarged view of the surface of the stone panel after rough finishing by the surface finishing method of the first comparative example. [Figure 6C] This is an enlarged view of the surface of the stone panel after rough finishing by the surface finishing method of the second comparative example.

Embodiments for Carrying Out the Invention

[0010] The embodiments for carrying out the surface finishing method of the stone panel of the present disclosure will be described as follows based on the drawings.

[0011] The stone panel 1 of this embodiment is attached to, for example, the wall surface or floor surface of a building and used as a surface material for a building or the like. As shown in FIG. 1, the stone panel 1 is formed of a stone formed in a panel shape having a predetermined stone thickness (thickness) and a predetermined size. Natural stone having a Mohs hardness of 3.0 or more and 7.0 or less is used as the stone for the stone panel 1. In particular, the stone is preferably granite or marble. And the surface 1a of the stone panel 1 is rough-finished by the surface processing device 100 shown in FIG. 2.

[0012] The surface processing device 100 is a water jet processing machine that performs surface processing of a workpiece with high-pressure water (liquid). As shown in FIG. 2, the surface processing device 100 includes a transfer table 101, a finishing mechanism 102, and a cleaning mechanism 103.

[0013] The transport platform 101 is equipped with multiple transport rollers 101a on its top plate. The stone panels 1 placed on the top plate move along a predetermined direction (transport direction X) as the transport rollers 101a rotate. The transport speed of the stone panels 1 by the transport platform 101 is set to be between 0.8 m / min and 1.2 m / min. The transport speed can be adjusted as appropriate within the range of 0.3 m / min and 2.0 m / min.

[0014] Above the conveyor table 101, the finishing mechanism 102 and the washing mechanism 103 are arranged in order along the conveying direction X of the stone panel 1. In other words, the finishing mechanism 102 is positioned upstream of the washing mechanism 103 in the conveying direction X.

[0015] The finishing mechanism 102 is a mechanism that uses water (liquid) to roughen the surface 1a of the stone panel 1. The finishing mechanism 102 includes a frame 102a extending in the width direction, a high-pressure pump 102b, and a water jet head 102c.

[0016] The high-pressure pump 102b is positioned separately from the transport platform 101 and the frame 102a, and increases the water pressure of room-temperature water supplied from a water source (not shown) before discharging it. The water discharged from the high-pressure pump 102b flows into the water jet head 102c via the hose 102d. Here, the water supplied to the high-pressure pump 102b is ordinary tap water that does not contain abrasives, or pure water.

[0017] The water jet head 102c is supported by the frame 102a and is capable of reciprocating along the extending direction of the frame 102a, i.e., the width direction. In this case, the height and position of the water jet head 102c along the transport direction X are fixed.

[0018] Water discharged from the high-pressure pump 102b is sprayed through the water jet head 102c. Here, the water jet head 102c is a gate-shaped hollow member, as shown in Figure 3A. The water jet head 102c has an opening in the center of its upper surface in the longitudinal direction, to which the hose 102d is connected. Furthermore, the water jet head 102c is connected to the hose 102d in a rotatable manner. The water jet head 102c is also provided with a plurality (12 in this case) of nozzles 102e on its bottom surface facing the transport table 101. Here, the plurality of nozzles 102e are arranged in groups of six at each end in the longitudinal direction of the water jet head 102c. The number and arrangement of the nozzles 102e are fixed for each water jet head 102c. However, the number of nozzles 102e is not limited to 12; for example, it could be 10 or 14, etc. Furthermore, multiple nozzles 102e may be evenly arranged across the entire bottom surface of the water jet head 102c. In other words, the number and arrangement of the nozzles 102e can be arbitrarily set.

[0019] Furthermore, the height of the water jet head 102c is set to a position such that the distance from the nozzle 102f of the nozzle 102e to the stone panel 1 placed on the conveyor table 101 is between 10 mm and 20 mm. Also, the distance from the nozzle 102f to the conveyor table 101 is set to a position such as between 30 mm and 110 mm. Note that the height of the water jet head 102c, i.e., the distance from the nozzle 102f to the stone panel 1, can be changed. The height of the water jet head 102c is set according to the material of the stone panel 1, the target surface roughness for the rough finish, etc.

[0020] The finishing mechanism 102 then sprays a nozzle at a pressure of 1200 kg / cm² towards the stone panel 1 placed on the transport table 101. 2 More than 2400kg / cm 2The ultra-high-pressure water (ultra-high-pressure liquid) set as described below is injected from the nozzle 102f of nozzle 102e. Here, "nozzle injection pressure" refers to the pressure at which water pressurized by the high-pressure pump 102b is discharged from the nozzle 102f of nozzle 102e. The ultra-high-pressure water injected onto the stone panel 1 has a nozzle injection pressure of 1500 kg / cm². 2 More than 2000kg / cm 2 The ultra-high pressure water should be set as follows. The nozzle injection pressure is set according to the material of the stone panel 1, the target surface roughness for the rough finish, etc.

[0021] Furthermore, when the finishing mechanism 102 sprays ultra-high-pressure water toward the stone panel 1 moving on the transport table 101, it rotates the water jet head 102c while moving it in the width direction. This allows the finishing mechanism 102 to uniformly apply ultra-high-pressure water to the entire surface 1a of the stone panel 1.

[0022] Furthermore, the widthwise movement speed of the water jet head 102c is set to a speed of 30 m / min or more and 60 m / min or less (20 times / min or more and 40 times / min or less). In other words, the nozzle 102f of the nozzle 102e moves in the widthwise direction at a movement speed of 30 m / min or more and 60 m / min or less. The widthwise movement speed of the water jet head 102c is set according to the material of the stone panel 1, the target surface roughness of the rough finish, etc.

[0023] Furthermore, the nozzle 102e's injection port 102f has a circular opening shape, as shown in Figure 3B. The diameter R of the injection port 102f is set to 0.35 mm here. As a result, the ultra-high-pressure water is ejected from the injection port 102f in a nearly straight line, and the trajectory cross-section is nearly circular.

[0024] The diameter R of the nozzle 102f is not limited to 0.35 mm. However, the smaller the diameter R of the nozzle 102f, the more likely it is to become clogged. Also, the larger the diameter R of the nozzle 102f, the lower the nozzle injection pressure, which increases the load on the high-pressure pump 102b. Therefore, it is desirable to set the diameter R of the nozzle 102f considering factors such as the likelihood of clogging and the load on the high-pressure pump 102b.

[0025] The cleaning mechanism 103 is a mechanism that cleans the rough-finished stone panel 1 by spraying water onto it. The cleaning mechanism 103 has a water supply pipe 103a that extends in the width direction which is perpendicular to the transport direction X, and a plurality of cleaning pipes 103b provided on the water supply pipe 103a.

[0026] Water flows into the water supply pipe 103a from a water source (not shown) via a hose 103c. The water supplied to the water supply pipe 103a is ordinary tap water that does not contain abrasives, or pure water. The water that flows into the water supply pipe 103a is sprayed onto the stone panel 1 via the washing pipe 103b. The washing pipe 103b is a flexible pipe with a nozzle 103d attached to its tip. The washing mechanism 103 sprays water onto the stone panel 1 as it moves on the transport table 101 by bending the washing pipe 103b at an arbitrary angle.

[0027] The basic procedure for manufacturing stone panel 1 is explained below, based on the basic manufacturing flow shown in Figure 4.

[0028] In step S1, a pre-selected raw stone is cut to a predetermined thickness and size to produce a stone panel 1. In other words, step S1 is a stone panel forming process in which the raw stone is cut and shaped into a stone panel 1 of a predetermined thickness. In step S1, if the irregularities of the surface 1a of the formed stone panel 1 deviate from a predetermined standard, the stone panel 1 may be roughly shaped after being cut from the raw stone until the irregularities of the surface 1a fall within the predetermined standard.

[0029] In step S2, following the shaping of the stone panel 1 in step S1, high-pressure water is sprayed onto the stone panel 1 to clean the surface 1a of the stone panel 1 with high-pressure water. This removes dirt such as iron sand and rust inhibitors that have adhered to the surface 1a of the stone panel 1. The water sprayed onto the stone panel 1 in step S2 is ordinary tap water that does not contain abrasives or pure water. In other words, step S2 is a sawn stone cleaning process in which the surface 1a of the shaped stone panel 1 is washed with water.

[0030] In step S3, following the cleaning of the stone panel 1 in step S2, the finishing mechanism 102 sprays ultra-high-pressure water onto the surface 1a of the stone panel 1 to roughen the surface 1a of the stone panel 1. At this time, the ultra-high-pressure water sprayed onto the stone panel 1 has a nozzle spray pressure of 1200 kg / cm². 2 More than 2400kg / cm 2 The following is set: Step S3 is a water jet finishing process in which ultra-high-pressure water pressurized by the high-pressure pump 102b is sprayed from the nozzle 102e to roughen the surface 1a of the stone panel 1. As a result, the stone panel 1 is roughened and extremely small, sharp (deep) irregularities are formed on the surface 1a.

[0031] Furthermore, water is sprayed onto the rough-finished stone panel 1 by the cleaning mechanism 103 to clean the surface 1a. In addition, the rough finish of the stone panel 1 is applied only to one side (surface 1a) of the stone panel 1, and not to the opposite side (back side).

[0032] In step S4, following the rough surface finish of stone panel 1 in step S3, the outer shape of stone panel 1 is finished.

[0033] In step S5, following the finishing of the outer shape of stone panel 1 in step S4, the shape of the end face of stone panel 1 is finished. The shape finishing of the end face of stone panel 1 refers to the processing of the corners of stone panel 1 and the joints where it connects with other stone panels 1.

[0034] In step S6, following the end face finishing of the stone panel 1 in step S5, the surface treatment of the stone panel 1 is performed. Note that the surface treatment of the stone panel 1 may include coating such as applying a penetrative water repellent to the surface 1a, or backlining treatment such as attaching a splash prevention sheet to the back surface of the stone panel 1. The surface treatment of the stone panel 1 may be applied to the entire surface of the stone panel 1, or may be applied only to the surface 1a with a rough finish. Note that the surface treatment of the stone panel 1 is performed as needed. That is, the surface treatment of the stone panel 1 is not necessarily performed and may not be performed. Then, the stone panel 1 is completed and the flow proceeds to the end.

[0035] Note that various inspections such as the quality and quantity of the stone panel 1 are appropriately performed between each step. Here, the "quality inspection" is an inspection of dimensions including the stone thickness of the stone panel 1, bending, warping, color, pattern, color unevenness, rust, scratches, etc.

[0036] The action of the surface finishing method of the stone panel 1 of the present disclosure is explained as follows.

[0037] In the present embodiment, the rough finish of the stone panel 1 by the finishing mechanism 102 of the surface processing apparatus 100 is performed by spraying ultra-high pressure water set to be 1200 kg / cm 2 or more and 2400 kg / cm 2 or less onto the surface 1a of the stone panel 1.

[0038] Thereby, for example, compared with the stone panel when rough finishing is performed by spraying high pressure water set to be 500 kg / cm 2 or more and 600 kg / cm 2 or less, the pressure received by the stone panel 1 during rough finishing becomes larger. Therefore, extremely minute and sharp irregularities are formed on the surface 1a of the stone panel 1 compared with the stone panel 1X (see FIG. 5A) when rough finishing is performed by spraying high pressure water set to be 500 kg / cm 2 or more and 600 kg / cm 2 or less (see FIG. 5C).

[0039] Furthermore, because the rough surface finish is achieved by spraying ultra-high-pressure water, the surface 1a of the stone panel 1 has an uneven surface, unlike the highly polished stone panel 1Y (see Figure 5B) which is polished to a mirror-like finish.

[0040] In other words, as shown in Figures 5A to 5C, the surface 1a of stone panel 1 is smoother than the surface 1a of stone panel 1X, and rougher than the surface 1a of stone panel 1Y. Note that in Figures 5A to 5C, the horizontal length of the drawings is the same.

[0041] Furthermore, since the irregularities formed on the surface 1a of the stone panel 1 are extremely small and sharp, for example, when the nozzle injection pressure is 500 kg / cm² 2 More than 600kg / cm 2 Compared to the stone panel 1X that has been roughened by spraying it with high-pressure water set as described below, diffuse reflection can be suppressed. As a result, the amount of specularly reflected light in stone panel 1 increases compared to stone panel 1X, and the amount of light that enters the viewer's eye decreases. In other words, the surface finishing method of stone panel 1 in this embodiment can give the surface 1a of stone panel 1 a darker color. Note that "giving a darker color" means bringing the color of the surface 1a of stone panel 1 closer to the color produced by polishing it to a mirror-like finish.

[0042] Furthermore, unlike the polished stone panel 1Y, the stone panel 1 has irregularities on its surface 1a, which allows for the suppression of gloss on surface 1a. Therefore, the surface finishing method for the stone panel 1 in this embodiment gives the surface 1a of the stone panel 1 a matte texture, allowing the viewer to perceive the texture of a rough finish.

[0043] Furthermore, the nozzle injection pressure is 2400 kg / cm². 2 If ultra-high-pressure water exceeding a certain limit is sprayed onto the stone panel 1, the surface 1a may be abraded, and the stone thickness may not be guaranteed. In contrast, in the surface finishing method for the stone panel 1 of this embodiment, the nozzle spray pressure during rough surface finishing is set to 2400 kg / cm². 2By setting the parameters as follows, it is possible to prevent a decrease in stone thickness due to roughening and to achieve an appropriate rough finish.

[0044] As a result, the surface finishing method for the stone panel 1 of this embodiment allows for a darker finish on the surface 1a of the stone panel 1 compared to the stone panel roughened by the surface finishing method of the first comparative example (see Figure 6B) and the stone panel roughened by the surface finishing method of the second comparative example (see Figure 6C), as shown in Figure 6A. Furthermore, the surface finishing method for the stone panel 1 of this embodiment allows for a reduced gloss on the surface 1a of the stone panel 1, while retaining the texture of a rough finish.

[0045] The rough surface finishing method for the first comparative example is what is known as "rough grinding." In this method, the stone panel 1 is washed with high-pressure water, and then the surface 1a of the stone panel 1 is polished with a relatively coarse grinding wheel, such as a diamond grinding wheel of about #20 to #30 grit, to achieve a rough surface finish. The rough surface finishing method for the second comparative example is what is known as "jet and polish." In this method, the stone panel 1 is washed with high-pressure water, and then the surface 1a of the stone panel 1 is heated with a gas burner set to about 1600°C to 2000°C while water is sprayed on it to perform a jet burner finish. After that, the surface 1a of the stone panel 1 is washed with water to achieve a rough surface finish.

[0046] Furthermore, in the surface finishing method for the stone panel 1 of this embodiment, the surface 1a of the stone panel 1 is finished with a darker color. Therefore, if the stone contains glossy minerals such as quartz, the brilliance of the glossy minerals can be made more prominent. Thus, the surface finishing method for the stone panel 1 of this embodiment makes the surface 1a of the stone panel 1 more lustrous than when it is roughened using the rough surface finishing method of the first comparative example or the rough surface finishing method of the second comparative example.

[0047] Furthermore, in the surface finishing method for the stone panel 1 of this embodiment, the rough surface finish of the stone panel 1 in the water jet finishing process is performed with a nozzle jet pressure of 1500 kg / cm². 2 More than 2000kg / cm 2 It is preferable to perform this by spraying ultra-high-pressure water as set below. This makes it possible to properly finish the surface 1a of the stone panel 1 with a dark color, and further reduces damage to the stone panel 1 caused by the ultra-high-pressure water. As a result, the appearance quality of the stone panel 1 can be further improved.

[0048] Furthermore, in the surface finishing method for the stone panel 1 of this embodiment, it is preferable to perform the rough surface finishing of the stone panel 1 in the water jet finishing process while conveying the stone panel 1 along a predetermined conveying direction X at a conveying speed set to 0.8 m / min or more and 1.2 m / min or less. This makes it possible to easily spray ultra-high-pressure water over the entire surface of the stone panel 1 while fixing the position of the nozzle 102e along the conveying direction X.

[0049] Furthermore, in the surface finishing method for the stone panel 1 of this embodiment, it is preferable that the roughening of the stone panel 1 in the water jet finishing process be performed while the stone panel 1 is being transported along a predetermined transport direction X, and the nozzle 102e is being moved along a direction perpendicular to the transport direction X at a travel speed set to 30 m / min or more and 60 m / min or less. This makes it possible to easily spray ultra-high-pressure water onto the entire surface 1a of the stone panel 1.

[0050] Furthermore, in the surface finishing method for the stone panel 1 of this embodiment, it is preferable that the stone to be processed is a natural stone with a Mohs hardness of 3.0 or more and 7.0 or less. This makes it possible to finish the surface 1a of the stone panel 1 with a deep color while retaining the texture of a rough surface finish by water jet finishing alone, without heating or polishing the stone panel 1 with a flame jet.

[0051] In particular, the stone material to be processed by the surface finishing method of the stone panel 1 of this embodiment is preferably granite or marble. The surface finishing method of the stone panel 1 of this embodiment can give the surface 1a of the stone panel 1, which is made of granite or marble, a particularly dark color.

[0052] The surface finishing method for stone panels described above has been explained, but the specific configuration is not limited to this embodiment. Modifications and additions to the design of the surface finishing method for stone panels described above are permitted as long as they do not depart from the spirit of the invention.

[0053] In this embodiment, examples were shown in which ordinary tap water without abrasives or pure water was used as the liquid sprayed onto the stone panel 1 in the waterjet finishing process. However, the liquid sprayed onto the stone panel 1 is not limited to water; for example, it may be water containing abrasives or a special solvent. Furthermore, the water (liquid) supplied to the high-pressure pump 102b may be filtered beforehand.

[0054] In this embodiment, the stone material used for the stone panel 1 is a natural stone material with a Mohs hardness of 3.0 to 7.0, and it is shown that granite or marble is preferable. However, the material of the stone material is not limited to these and can be arbitrarily selected, and is not limited to natural stone material.

[0055] In this embodiment, an example is shown in which the surface processing apparatus 100 is equipped with a cleaning mechanism 103. However, the cleaning mechanism 103 does not necessarily have to be provided in the surface processing apparatus 100. [Explanation of symbols]

[0056] 1. Stone panel 1a surface 100 Surface processing equipment 101 Transport platform 102a Mounting frame 102b High-pressure pump 102c Water Jet Head 102e Nozzle 102f injection nozzle

Claims

1. The stone panel forming process involves cutting pre-cut raw stone to form stone panels of a predetermined thickness, A water jet finishing process is performed on the molded stone panel by spraying a liquid pressurized by a high-pressure pump from a nozzle to roughen the surface of the stone panel. In a surface finishing method for stone panels, In the water jet finishing process, the rough surface finish is performed with a nozzle jet pressure of 1200 kg / cm². ２ Above, 2400kg / cm ２ This is done by injecting ultra-high pressure liquid as set below. A method for surface finishing stone panels, characterized by the features described above.

2. In the surface finishing method for stone panels according to claim 1, In the water jet finishing process, the rough surface finish is performed when the nozzle jet pressure is 1500 kg / cm². ２ Above, 2000kg / cm ２ This is done by injecting ultra-high pressure liquid as set below. A method for surface finishing stone panels, characterized by the features described above.

3. In the surface finishing method for a stone panel described in claim 1 or claim 2, The rough surface finishing in the waterjet finishing process is performed while the stone panel is transported along a predetermined transport direction at a transport speed set to 0.8 m / min or more and 1.2 m / min or less. A method for surface finishing stone panels, characterized by the features described above.

4. In the surface finishing method for a stone panel described in claim 3, The roughening process in the waterjet finishing step is performed by moving the nozzle along a direction perpendicular to the conveying direction at a travel speed set to 30 m / min or more and 60 m / min or less. A method for surface finishing stone panels, characterized by the features described above.

5. In the surface finishing method for a stone panel described in claim 1 or claim 2, The aforementioned stone material is a natural stone material with a Mohs hardness of 3.0 or more and 7.0 or less. A method for surface finishing stone panels, characterized by the features described above.

6. In the surface finishing method for a stone panel described in claim 5, The aforementioned stone material is granite or marble. A method for surface finishing stone panels, characterized by the features described above.

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