Composite Stone Mix Distributor With Adjustable Lamination Rolls
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Solution Overview
Problem
Existing mix distributor devices for manufacturing composite stone slabs suffer from non-uniform distribution, flaking, and difficulty in achieving uniform coloration and small thickness, leading to increased compaction time and aesthetic inconsistencies.
Innovation Solution
A distributor device with adjustable lamination rolls and controlled mixing mechanisms ensures uniform layer deposition, prevents flaking, and allows for continuous longitudinal streaks and interchangeable slab sides, facilitating compacting of slabs with thicknesses less than 10 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mix distributor devices are used, then the distribution process is simple, but the mix layer is non-uniform and flaking occurs
Solution Approach 1:
The mix is preliminarily laminated between two conveyor belts before being distributed onto the support. This preliminary lamination action ensures uniform distribution and prevents flaking during the subsequent compaction process, while the conveyor belts are designed to be replaceable to maintain functionality over time
Solution Approach 2:
Two conveyor belts are introduced as intermediary elements between the mix source and the support. These belts serve as a mediating medium that enables uniform distribution of the mix while preventing direct contact that would cause flaking. The belts are designed with specific properties (anti-adhesive coating, replaceability) to fulfill their intermediary function
2Productivity
If the mix is distributed by conventional methods, then the process is fast, but compaction time increases due to non-homogeneous mix
Solution Approach 1:
The mix is preliminarily laminated between conveyor belts at controlled speed before distribution. This preliminary action ensures homogeneous mix structure that requires less compaction time, thereby maintaining high distribution speed while reducing the subsequent compaction duration
Solution Approach 2:
The conveyor belts are designed with adjustable speed and replaceable components that allow optimization of the lamination process. The dynamic adjustment of belt speed and the ability to replace worn belts ensure consistent mix quality that minimizes compaction time while maintaining high productivity
3Manufacturing precision
If conventional distributors are used, then the device structure is simple, but coloration uniformity and streaking effects cannot be achieved
Solution Approach 1:
Coloring agents are applied to the mix while it is being laminated between the conveyor belts. This preliminary action ensures uniform color distribution and enables controlled streaking effects. The lamination process simultaneously ensures even thickness and consistent coloration throughout the mix layer
Solution Approach 2:
The conveyor belts serve as an intermediary platform that allows integration of coloring agent application systems. The belts' flat surface and controlled movement enable precise colorant distribution while maintaining mix uniformity, achieving both coloration uniformity and aesthetic streaking effects
4Adaptability or versatility
If thick slabs are manufactured, then the structure is more stable, but small thickness slabs less than 10 mm cannot be formed
Solution Approach 1:
The conveyor belts are designed with adjustable speed and position, allowing dynamic control of the mix layer thickness during lamination. This dynamic adjustment enables production of slabs with varying thicknesses, including thin slabs less than 10 mm, while maintaining structural stability through precise control
Solution Approach 2:
The system allows change of critical parameters including belt speed, belt position, and lamination pressure. By adjusting these parameters, the mix layer thickness can be precisely controlled to produce slabs of any desired thickness while maintaining uniform distribution and preventing flaking
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 device achieves uniform mix distribution, reduces compaction time, and ensures both slab sides have identical appearances, enabling efficient production of aesthetically consistent slabs with desired color effects.
Implementation Method 1
a first lamination roll (18) and a second lamination roll (20) rotatable about respective horizontal axes (Y1, Y2) transverse with respect to the feeding direction (X)... the second lamination roll (20) being provided with adjustment means (23) for moving said second roll (20) towards and away from said first roll (18)
Implementation Method 2
an extractor belt (8)... able to receive the mix (L) from said outlet opening (6) and transport it towards said support (S) in said longitudinal feeding direction (X)
Implementation Method 3
The supports and the distributor move relative to each other so as to allow the mix to be deposited along the whole length of the support
Data Source
Figure 1
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AI summary
A distributor device (1) for distributing a mix (L) in one or more forming supports (S) for manufacturing articles made of composite stone material. The device (1) comprises mix supply means (10) designed to transport the mix (L) along a longitudinal feeding direction (X) towards the forming supports (S). The distribution device (1) further comprises mix lamination means (16) located between the supply means (10) and the supports (S). The invention also relates to a method and a plant for manufacturing articles made of composite stone material which use the aforementioned distributor device (1).