Method of Producing Slabs of Artificial Stone and Polymerisable Resin Having a Veined Effect By Means of Vibro-Compression Under Vacuum

• US 20080315448A1
• Filed: 06/15/2005
• Published: 12/25/2008
• Est. Priority Date: 06/15/2005
• Status: Active Grant

• Current Assignee: Cosentino Research And Development SL
• Original Assignee: Cosentino SA (Grupo Cosentino Sl)
• Inventors: Cruz, Juan
• Granted Patent: US 7,815,827 B2
• Time in Patent Office: Days
• US Class Current: 264/71
• CPC Class Codes: B28B 1/005 Devices or processes for obtaining articles having a marble appearance producing decorative effects B44C; design of stone surfaces, e.g. marble, B44F9/04
• CPC Class Codes: B29C 67/244 by vibrating the composition before or during moulding
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2111/54 Substitutes for natural stone, artistic materials or the like
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0067 making use of vibrations
• CPC Class Codes: C04B 40/0071 making use of a rise in pressure
• CPC Class Codes: C04B 40/0089 making use of vacuum or reduced pressure

Abstract

The invention relates to a process for manufacturing artificial stone boards with polymerizable resins with a “veined effect” by means of the vibro-compaction under vacuum system comprising a first grinding phase of the different materials forming the filler, a second phase containing a resin with the catalyst and optionally a third phase consisting of the mixing of the two previous phases until the homogenization of the materials with the resin, a fourth phase of moulding and compaction of the obtained paste by vibro-compression under vacuum, a fifth hardening phase by polymerization of the resin by means of heating and a last cooling, cutting and polishing phase.

Claims

1-9. -9. (canceled)

10. A process for manufacturing artificial stone slabs having a veined effect comprising the following steps:

(a) grinding different materials of varied granulometry so as to form a filler;

(b) obtaining a composition comprising a polymerizable and thermosetting resin, and optionally a catalyst, an accelerator, a binder and a coloring agent;

(c) mixing the filler of step (a) with the composition of step (b) so as to obtain a homogeneous mixture;

(d) transporting the homogeneous mixture of step (c) by means of a belt to a distributor;

(e) discharging, from the distributor to a mould, an amount of said mixture necessary for making a slab according to the dimensions of the mould;

(f) protecting the mixture with paper, or an elastomer;

(g) moulding and pressing the mixture in each mould by compaction using vibro-compression under vacuum;

(h) hardening, by polymerizing the resin in the resulting molded and pressed mixture of step (g) by means of heating in an oven between 80°

C. and 110°

C. so as to obtain a slab;

(i) cooling, calibrating, polishing and cutting said slab;

wherein a coloring agent is incorporated in step (c) during mixing;

during transporting in step (d) or in the distributor itself;

or during step (e); and

said coloring agent is incorporated by injecting in liquid form under pressure, such that the obtained slab has veins of said coloring agent in all its surfaces.

11. The process according to claim 10, wherein the coloring agent is a solid pigment.

12. The process according to claim 11, wherein the coloring agent is a solid pigment having a granulometry of less than 0.7 mm.

13. The process according to claim 10, wherein the coloring agent is a liquid coloring agent or a dissolved solid pigment forming a liquid solution.

14. The according to claim 13, wherein the coloring agent is incorporated by means of an arm which sprays such onto the mixture.

15. The process according to claim 13, wherein the coloring agent is dissolved in the polymerizable and thermosetting resin of step (b).

16. The process according to claim 13, wherein the coloring agent is dissolved in a monomer compatible with the polymerizable and thermosetting resin of step (b), incorporating the accelerator, catalyst and binder as in step (b).

17. The process according to claim 10, wherein the mixture is protected with Kraft paper or a rubber layer before being pressed.

18. A slab obtained by the process according to claim 10, wherein said slab has a veined effect in all its faces.