Artificial Stone Slabs Through Atomized Silicate Compaction
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Solution Overview
Problem
Existing methods for producing artificial stone slabs face challenges in creating large, thin slabs with adequate resistance and reduced weight, leading to potential cracks, breakages, and increased production rejects, while also being resource-intensive and environmentally impactful.
Innovation Solution
A method involving the grinding of silicate-rich inert materials, atomization, compacting under high pressure, and controlled heating, followed by reinforcement with a thin adhesive layer, to produce slabs with a thickness less than 3 mm, optimized for strength and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the slab is reduced to decrease weight, then the weight is contained, but the resistance of the slab deteriorates, involving possible cracks and breakages
Solution Approach 1:
The invention uses composite materials by combining ceramic granules (inert material with silicates and aluminium oxide) with organic binders in specific proportions. This composite structure allows the thin slab to maintain high resistance despite reduced thickness, as the combination of ceramic particles and binding agents creates a reinforced matrix that prevents cracks and breakages while keeping the slab thin and lightweight.
Solution Approach 2:
The invention changes key parameters of the material composition, specifically requiring inert material with aluminium oxide content of at least 25% by weight and controlling the grain size distribution (with 70% by weight being coarse fraction >300 μm). These parameter changes optimize both the mechanical strength and weight characteristics, enabling thin slabs to achieve adequate resistance without increasing thickness.
2Weight of moving object
If the thickness of the slab is reduced to decrease weight, then the weight is contained, but the reliability of production deteriorates, increasing production rejects
Solution Approach 1:
The invention establishes specific parameter ranges for reliable production: aluminium oxide content ≥25%, coarse fraction (＞300 μm) comprising 70% by weight, and controlled organic binder content. These parameter specifications ensure consistent quality and reduce production rejects by preventing defects during manufacturing, transport, and installation, thereby improving production reliability while maintaining thin slab weight advantages.
3Length of moving object
If conventional production methods are used to maintain high dimensions, then the dimensions are achieved, but the weight reduction is limited
Solution Approach 1:
The composite ceramic formulation with optimized grain size distribution (70% coarse fraction ＞300 μm) and specific aluminium oxide content enables the production of large-format slabs with reduced thickness. This allows achieving high dimensions while significantly reducing weight, as the reinforced composite structure compensates for the reduced thickness that would otherwise compromise structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of high-quality, large-format slabs with improved resistance, reduced environmental impact, and lower material costs, while maintaining productivity and reducing production defects.
Implementation Method 1
grinding an inert material comprising silicates having an aluminium oxide content greater than or equal to 25% by weight, until a mixture of granulated material is obtained
Implementation Method 2
spraying and drying a suspension comprising said granulated material by means of an atomizing device until an atomized material is obtained
Implementation Method 3
heating the slab of compacted material to a temperature between 50° C. and 1250° C. for a time period of less than or equal to 45 min and greater than or equal to 10 min in order to obtain a slab of consolidated material
Data Source
AI summary
The present invention relates to a method (900) for producing artificial stone slabs comprising grinding (901) an inert material comprising silicates having an aluminium oxide content greater than or equal to 25% by weight, until a mixture of granulated material is obtained in which a coarse fraction of granules, having a diameter greater than 300 μm, is 70% by weight of the total weight of the mixture. The method (900) further comprises spraying and drying (902) a suspension comprising the granulated material by means of an atomizing device until an atomized material is obtained. Furthermore, the method comprises depositing (903) the atomized material on at least one movable surface of a compacting device and compacting (904) the atomized material on the movable surface, to obtain a slab of compacted material. The method (900) further comprises heating (906) the slab of compacted material to a temperature between 50° C. and 1250° C., for a time period of less than or equal to 45 min and greater than or equal to 10 min, to obtain a slab of consolidated material.