Artificial Agglomerate Slab Veining With Robotic Groove Filling
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Solution Overview
Problem
Existing methods for manufacturing artificial agglomerate stone slabs struggle to efficiently produce novel veined aesthetic effects that resemble natural marble patterns, lacking reproducibility and industrial efficiency.
Innovation Solution
A method involving a first robotic device with a conical tool to create grooves in a mixture layer, followed by dispensing a second mixture into these grooves, and compacting both mixtures to form slabs with visible veined effects on the surface and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods using templates or tools to create cavities/furrows are used, then veined effects can be created in artificial agglomerate slabs, but the process lacks reproducibility and industrial efficiency
Solution Approach 1:
The patent replaces traditional mechanical template-based cavity creation with a robotic system that uses a dispensing nozzle to directly deposit the second mixture into groove patterns. The robotic arm with programmable motion control substitutes manual or tool-based mechanical cavity formation, enabling precise, reproducible, and efficient veined effect creation at industrial scale.
Solution Approach 2:
The patent changes the approach from creating physical cavities first to directly dispensing material into groove patterns. By controlling the robotic dispensing parameters (speed, deposition rate, nozzle position, mixture viscosity), the process achieves reproducible veined effects with improved industrial efficiency, transforming the manufacturing parameters rather than the fundamental process steps.
2Manufacturing precision
If combinations of different pigmented mixtures are separately distributed and compacted, then veined aesthetic effects can be achieved, but the process is complex and lacks reproducibility
Solution Approach 1:
The robotic dispensing system serves multiple functions: it creates the groove patterns, deposits the second mixture with precise control, and can be programmed to reproduce identical veined patterns across different slabs. This single multi-functional system replaces multiple separate operations (template application, cavity creation, manual filling), reducing overall process complexity while maintaining aesthetic precision.
Solution Approach 2:
The robotic system incorporates feedback control through programmable motion paths and deposition parameters. The system can be programmed with precise trajectories for groove creation and filling, ensuring reproducible veined effects. Sensors and control systems monitor and adjust parameters during the process to maintain consistent aesthetic quality across production batches.
Data Source
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AI summary
The present disclosure relates to artificial stone having chromatic effects and used for counters, kitchen tops, sinks, shower trays, wall cladding, flooring or the like. Particularly, it relates to a method for manufacturing an artificial agglomerate material slab (9) comprising the following steps: a) dispensing a first layer (6) of a first mixture (6.2) onto a surface; b) creating groove(s) (6.1) in the first layer (6) by a first tool (1), mounted on a first robotic device (5); c) dispensing a second mixture into the groove(s) (6.1); and d) compacting and hardening the combination of first and second mixture; wherein the first tool (1) comprises a first conical element (2), which is moved in translation through the first layer (6) by the first robotic device(5) along a predetermined path and is rotated by first rotation means (5.1) at the same time. A production system for the manufacture of artificial agglomerate material slabs (9) is also claimed.