Method for the production of solid surfaces for construction
AssigneeCosentino Research Ana Development, S.L
InventorsJose Manuel Benito Lopez, Juan Antonio Jara Guerrero
Life of this patent
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Abstract
The invention relates to a method for the production of solid surfaces for construction, in particular large boards made from completely inorganic components, for use as kitchen worktops, bathroom surfaces, building cladding materials, flooring and for other uses related to the field of construction. The invention is suitable for both indoor and outdoor environments.
Claims18
A method for the production of compacted slabs or boards made from an inorganic material for construction comprising the following phases:
- a) storing raw materials,
- b) controlled metering of different materials,
- c) dry milling or wet milling the materials,
- d) storing the mixture and/or formulation obtained in step c),
- e) processing and adding color pigments to a proportion of the mixture and/or formulation stored in d), obtaining a colored mixture and/or formulation,
- f) mixing the initial formulation with the colored formulation (obtained in step e), obtaining a colored mixture,
- g) in the case of wet milling, drying by atomization until obtaining a homogeneous colored powder with a specific particle size and moisture,
- h) storing the different colored powders, maintaining their corresponding moisture level or wetting them depending on the type of milling process performed,
- i) metering the different colored powders on a conveyor belt and applying different embellishments in the volume and on the surface,
- j) compacting the colored powders,
- k) sizing the end part by means of cutting,
- l) surface embellishment process,
- m) pressing the colored powders, optionally providing embossment to the end part by means of incorporating a structure on the pressing surface,
- n) embellishing the surface of the pressed board which can be carried out before and/or after the drying process,
- o) drying,
- p) cooking the embellished board, and
- q) calibrating, polishing, cutting or beveling edges of the board.
The method according to any of the preceding claims, characterized in that the grain size of the inorganic material is less than 500 mm.
The method according to any of the preceding claims, characterized in that the raw material of step a) comprises at least the following formulation in % by weight of the final mixture:
- clays=10-60%
- feldspars=5-80%
- kaolins=5-40%
- glass materials=0-35%
- recycled materials=5-15%.
The method according to any of the preceding claims, characterized in that the metering step is carried out through conveying elements selected form the group consisting of conveyor belts, electric discharge and/or pneumatic conveying systems.
The method according to any of the preceding claims, characterized in that the milling step is dry milling through hammer or pendulum mills.
The method according to any of the preceding claims, characterized in that in coloring step e) a fraction thereof is homogeneously mixed with an amount of 0.1% to 20% by weight of pigments selected from the group consisting of iron oxide, copper oxide, cobalt oxide and/or chromium oxide.
The method according to any of the preceding claims, characterized in that the drying step is carried out in a drying tower for drying by atomization at 600° C.
The method according to any of the preceding claims, characterized in that in step h) the moisture level of the powder obtained in step g) is kept between 4-8%.
The method according to any of the preceding claims, characterized in that embellishing step i) is carried out through addition and controlled distribution of layers, veins, granules and strata.
The method according to any of the preceding claims, characterized in that compacting step j) is performed through a pressing station applying a continuous pressure of between 50 to 90 kg/cm2.
The method according to any of the preceding claims, characterized in that pressing step m) is performed through a hydraulic press using a pressure of 550 kg/cm2.
The method according to any of the preceding claims, characterized in that cooking step p) is carried out in a roller kiln at a temperature not greater than 1600° C.
Dependencies are inferred from the claim text.