Multi-layer slab product made of stone granulates and relative manufacturing process
First Claim
1. A process for the preparation of a multi-layer composite slab product, comprisingfirst and second dense layers of stone material agglomerate and binding agent;
- and an expanded material layer in direct contact with the first and second layers and intermediate the first and second layers, the first and second dense layers being surface layers, and the expanded material layer being less dense than each of the first and second dense layers comprising the following steps;
distribution of a stone material agglomerate together with a binding agent in a mold or on a molding belt to form a first, lower layer of the product;
prior to any vibro-compression, positioning on said first layer at least one pre-cast support made of expanded agglomerate and a binding agent to form an intermediate layer of the product;
distribution of a further stone material agglomerate together with a binding agent on said at least one pre-cast layer to form at least a second, upper layer of the product;
vibro-compression, in a single step, of said stone material agglomerates and binding agents and of said at least one pre-cast support; and
hardening of the mixture via thermal reaction.
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Accused Products
Abstract
The invention concerns a product and the relative manufacturing process, said product, including at least a precast support (2) of expanded material and at least a layer (3) of agglomerated stone material in form of granulates bound by a binding phase, over at least one surface of said expanded support (2). According to suitability, the product (1) is made by a sandwich structure with an intermediate layer of expanded material and two surface coatings of stone material. The product (1) can also have a complex or modular shape, from which it is possible to cut and eventually to work finished pieces of predetermined dimensions. The main advantage of the invention consists in obtaining a finished product (1, 10, 100) lighter than a product made of agglomerated stones homogeneous in the thickness.
38 Citations
20 Claims
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1. A process for the preparation of a multi-layer composite slab product, comprising
first and second dense layers of stone material agglomerate and binding agent; - and
an expanded material layer in direct contact with the first and second layers and intermediate the first and second layers, the first and second dense layers being surface layers, and the expanded material layer being less dense than each of the first and second dense layers comprising the following steps;
distribution of a stone material agglomerate together with a binding agent in a mold or on a molding belt to form a first, lower layer of the product;
prior to any vibro-compression, positioning on said first layer at least one pre-cast support made of expanded agglomerate and a binding agent to form an intermediate layer of the product;
distribution of a further stone material agglomerate together with a binding agent on said at least one pre-cast layer to form at least a second, upper layer of the product;
vibro-compression, in a single step, of said stone material agglomerates and binding agents and of said at least one pre-cast support; and
hardening of the mixture via thermal reaction. - View Dependent Claims (2)
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3. A multi-layer composite slab, comprising:
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first and second dense layers of a first material agglomerate and a first binding agent; and
an expanded material layer in compressive direct contact with the first and second layers and intermediate the first and second layers, the second layer being of an expanded material agglomerate and a second binding agent, the first and second dense layers being surface layers, and the expanded material layer being less dense than each of the first and second dense layers. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of preparing a multi-layer composite slab product, comprising the steps of:
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surrounding a pre-cast support made of an expanded agglomerate and a first binding agent within a mixture of stone agglomerates and second binding agent; and
vibro-compressing, in a single step, the mixture of stone material agglomerates and second binding agent, wherein a multi-layer composite slab is formed comprising first and second dense layers of the stone material agglomerates and second binding agent sandwiching the pre-cast support, the pre-cast support being an expanded material layer in direct contact with the first and second layers and intermediate the first and second layers, the first and second dense layers being surface layers, and the expanded material layer being less dense than each of the first and second dense layers. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification