Thin Artificial Stone Slabs Using Controlled Granule Sizing
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Solution Overview
Problem
Existing methods for producing artificial stone slabs face challenges in creating large dimensions with a small thickness, leading to reduced weight and increased susceptibility to cracks and breakages, while also being inefficient and environmentally costly.
Innovation Solution
A method involving grinding inert materials with high aluminum oxide content, atomizing and compacting the material under controlled pressure, followed by precise heating and reinforcement with a thin adhesive layer to produce slabs with a thickness less than 3 mm, ensuring high resistance 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 decreases leading to cracks and breakages
Solution Approach 1:
The patent applies composite materials by combining ceramic granulated material with specific binding agents and additives to create a multi-component mixture. This composite formulation enables the production of slabs with thickness less than 3mm that maintain high resistance and mechanical strength despite the reduced thickness, thereby resolving the contradiction between weight reduction and strength preservation
Solution Approach 2:
The patent changes key parameters including the chemical composition of the mixture (aluminium oxide content greater than or equal to 25% by weight), heating temperature (between 50°C and 1250°C), and particle size distribution (coarse fraction greater than 300 μm diameter representing 70% by weight). These parameter changes enable thin slabs to achieve optimal strength-to-weight ratio and resistance without cracks or breakages
2Weight of moving object
If the thickness is reduced to less than 3 mm to achieve weight reduction, then weight is contained, but the reliability decreases due to increased susceptibility to defects
Solution Approach 1:
The patent applies preliminary action through a controlled heating process that consolidates the compacted material before final slab formation. By heating the compacted material to temperatures between 50°C and 1250°C for optimized time periods, the material undergoes consolidation that pre-strengthens it, ensuring high reliability and resistance to cracks and breakages in the final thin slab product
Solution Approach 2:
The patent optimizes critical parameters including aluminium oxide content (≥25% by weight), particle size distribution (70% coarse fraction >300 μm), and heating temperature ranges. These parameter changes ensure that even at thickness less than 3mm, the slabs achieve the necessary reliability and resistance to defects during production, transport, and installation
3Area of stationary object
If conventional production methods are used to maintain large dimensions, then the dimensions are achieved, but the thickness must be increased which increases weight
Solution Approach 1:
The patent uses composite materials with optimized ceramic granulated content and binding agents that provide high structural integrity. This allows the production of large-dimensional slabs with thickness less than 3mm, achieving the desired area coverage without the weight penalty that would normally accompany increased thickness in conventional products
4Manufacturing precision
If the heating time is extended to improve consolidation, then the consolidation quality improves, but the production time increases
Solution Approach 1:
The patent optimizes the heating parameter by establishing a temperature range between 50°C and 1250°C with optimized time periods. This parameter optimization achieves complete consolidation of the compacted material while minimizing production time, thereby improving manufacturing precision without excessive time loss and maintaining high productivity
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, cost-effective, and environmentally friendly artificial stone slabs with optimized dimensions, reduced material usage, and improved productivity.
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
compacting the atomized material on the movable surface of a compacting device in order to obtain a slab of compacted material
Implementation Method 4
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
Figure 1
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.