Veined Stone Slab Manufacturing with Extractor Belt Dispensing
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Solution Overview
Problem
Existing methods for manufacturing conglomerate stone slabs, such as Bretonstone and Lapitech technologies, fail to achieve a pronounced and random veined effect throughout the thickness of the slabs, resulting in blurred veining and difficulties in changing the veining effect, especially with liquid colorants and powdery distribution.
Innovation Solution
An apparatus and method involving a hopper with a discharge gate and an extractor belt for distributing a mix with a powdery coloring substance using a dispensing device with flexible strips and a spreading device, ensuring random distribution and penetration of the coloring agent into the mix, allowing for a clear and defined veining effect throughout the slab's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spiking apparatus is used to distribute coloring agent after vacuum vibrocompression, then the veining effect is achieved on the surface, but the veining effect does not penetrate throughout the thickness of the slab
Solution Approach 1:
The coloring agent is distributed onto the mix before the vacuum vibrocompression step, rather than after. This preliminary distribution allows the coloring agent to be incorporated into the mix structure before compression, enabling deeper penetration throughout the slab thickness while maintaining distribution control
Solution Approach 2:
The patent changes the timing parameter of the coloring agent distribution from post-compression to pre-compression. This parameter change allows the coloring agent to be distributed when the mix is still in a less dense state, facilitating deeper penetration during the subsequent compression process
2Manufacturing precision
If liquid coloring agent is used with a weighing distributor, then the veining effect is achieved, but the veining becomes blurred and the pigment diffuses within the mix mass
Solution Approach 1:
The patent changes the physical state parameter of the coloring agent from liquid to powdery form. This parameter change prevents the diffusion and blurring effects associated with liquid pigments, while the powdery form can be effectively distributed using the extractor belt mechanism to achieve sharp, well-defined veining
Solution Approach 2:
The patent replaces the weighing distributor mechanism with an extractor belt system. This mechanical substitution eliminates the mixing action that causes pigment diffusion, while the belt extraction mechanism provides controlled distribution of the powdery coloring agent for sharp veining definition
3Manufacturing precision
If powdery coloring substance is distributed using conventional methods, then the veining effect is achieved, but the distribution is not random and uniform throughout the mix
Solution Approach 1:
The extractor belt imparts a vibratory movement to the mix during the coloring agent distribution process. This vibration facilitates random and uniform distribution of the powdery coloring substance throughout the mix, simulating natural stone veining patterns while maintaining ease of operation through automated belt control
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 solution achieves a pronounced and random veined effect similar to natural stone, facilitating easy changes in veining effects by ensuring uniform distribution and penetration of the coloring agent, improving the appearance and versatility of the slabs.
Implementation Method 1
conveyed by said extractor belt towards a position where it falls freely onto said temporary moulding support
Implementation Method 2
a vibratory movement at a predetermined frequency is imparted to the press ram
Data Source
AI summary
Means for dispensing a powdery coloring substance onto the surface of a mix comprising stone, stone-like, glass or ceramic material. The means comprise at least one dispensing device for containing and dispensing a powdery coloring substance and at least one spreading device. The spreading device comprises at least one moving perforated plate which receives a metered amount of said coloring substance from the dispensing device and distributes it over the surface of the mix.