WO2016115884A1 - 一种重锤拍击式合成石成型机及加工工艺 - Google Patents

一种重锤拍击式合成石成型机及加工工艺 Download PDF

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Publication number
WO2016115884A1
WO2016115884A1 PCT/CN2015/087371 CN2015087371W WO2016115884A1 WO 2016115884 A1 WO2016115884 A1 WO 2016115884A1 CN 2015087371 W CN2015087371 W CN 2015087371W WO 2016115884 A1 WO2016115884 A1 WO 2016115884A1
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WIPO (PCT)
Prior art keywords
synthetic stone
aggregate
hammer
synthetic
plate
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Ceased
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PCT/CN2015/087371
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English (en)
French (fr)
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WO2016115884A9 (zh
Inventor
杨绍良
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Shanghai Unlimit Materials Co Ltd
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Shanghai Unlimit Materials Co Ltd
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Publication date
Application filed by Shanghai Unlimit Materials Co Ltd filed Critical Shanghai Unlimit Materials Co Ltd
Priority to CA2974443A priority Critical patent/CA2974443C/en
Priority to EP15878554.3A priority patent/EP3246142A4/en
Priority to AU2015378186A priority patent/AU2015378186A1/en
Priority to US15/544,499 priority patent/US10695948B2/en
Publication of WO2016115884A1 publication Critical patent/WO2016115884A1/zh
Anticipated expiration legal-status Critical
Publication of WO2016115884A9 publication Critical patent/WO2016115884A9/zh
Priority to AU2019204700A priority patent/AU2019204700B2/en
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • B29C67/244—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length by vibrating the composition before or during moulding

Definitions

  • the invention relates to a synthetic stone forming equipment and a processing technology, in particular to a heavy hammer tapping synthetic stone forming equipment and a processing technology without a pressure system.
  • Natural stone is an important part of building materials. Because of its diversified colors and easy development, natural stone has been widely used since ancient times. However, with the excessive increase of mining volume and low utilization rate, the exploitation of natural stone is gradually restricted. Especially in European countries, the exploitation of natural stone has been banned. Moreover, the products and varieties of each mineral area are unique, which increases the difficulty of its use. People have been looking for alternatives. With the development of the economy, the building decoration materials are changing with each passing day, and the synthetic stone has great development opportunities as a new type of decorative material. However, the use of the pressurization system and the vibration system of the production equipment is a technical problem, resulting in complicated equipment manufacturing, unstable production operation, high maintenance repair rate, and the production efficiency cannot be scaled up.
  • the utility model patent of China Patent No. CN201120319813.9 discloses an artificial quartz stone pressing machine, which comprises a machine base, a frame mounted on both sides of the machine base, a shock absorbing spring mounted on the bottom of the machine base, and mounted on the machine.
  • a frame and a punch on the seat the guide base is provided with a guide pillar, and the sleeve and the punch are provided with a sleeve, and the frame and the punch are movably connected to the guide pillar through the sleeve, and the upper end of the guide pillar
  • the organic top is fixed, and a punch hydraulic cylinder and a surrounding hydraulic cylinder are arranged on the top of the machine.
  • the hydraulic cylinder of the punch is connected to the punch through the hydraulic cylinder connecting seat, and the hydraulic cylinder of the surrounding frame is connected to the surrounding frame through the hydraulic cylinder connecting seat.
  • a vacuum sealing strip is arranged at the bottom of the frame and the connection portion with the punch, and a vibration motor is arranged on the punch; a transmission belt is arranged above the frame and the base, and a transmission wheel is arranged at both ends of the transmission belt.
  • the pressure is applied by the hydraulic pressure, and then the vibration is vibrated by the vibration motor.
  • the pressure plate method has the following disadvantages. Since the vibration motor is a high-frequency vibration operation, the hydraulic system is always in the process of pressurizing and releasing.
  • the hydraulic pressure has been in a state of virtual pressure and it is impossible to apply sufficient pressure to the sheet.
  • the vibration system causes long-lasting continuous damage to the stability of the machine. In order to meet the sheet metal forming, it takes a lot of time to waste between.
  • the above technical solution can be called the “compression + vibration” synthesis method.
  • the problem that the whole industry has to solve is how to combine the pressure and vibration force, but this problem has not been solved, which seriously affects the development of synthetic stone forming equipment. There is always a lack of a mature, large-scale application, fast forming synthetic stone forming equipment and process.
  • the technical problem to be solved by the present invention is to overcome the deficiencies of the prior art described above, and to provide a heavy hammer tapping synthetic stone forming machine with high synthetic force, fast forming speed, good compactness and simple structure, and at the same time provide a The heavy hammer slap of the loose synthetic stone mixture under vacuum is processed into a sheet.
  • a hammer tapping synthetic stone forming machine includes a base, a weight mounted on the base, and a drive for driving the weight, the base having a loading zone thereon, The weight taps the loading zone.
  • a hammer tapping synthetic stone forming machine further has the following subsidiary technical features:
  • the weight includes a hammer plate in contact with the synthetic stone mixture in the loading zone and a weight plate located on the hammer plate and adding weight, the weight plate being coupled to the hammer plate.
  • the hammer plate is provided with a plurality of supports, and the hammer plate is coupled to the load plate through the support.
  • the weight plate is formed by laminating a plurality of load-bearing plates.
  • the hammer plate is further provided with a mold frame, and a periphery of the mold frame is mounted with a hanging member, and the hanging member is hooked on the hammer plate.
  • a lifting device is disposed on the base, and the lifting device is coupled to the weight.
  • the driver is disposed on the weight, and the driver is constructed by a plurality of drivers being synchronously connected together.
  • a plurality of the drives are synchronously coupled together to form a set of synchronous drive groups, and the weight is provided with at least one set of synchronous drive groups.
  • the synchronous drive groups are arranged in the same layer or in a layered arrangement.
  • the driver is mounted on the hammer plate and/or on the load plate.
  • a heavy hammer tapping synthetic stone processing process includes the following steps:
  • A the ingredients, the synthetic stone mixed aggregate, the filler and the binder are mixed according to the ratio to form a synthetic stone mixture
  • the hammer hammering synthetic stone processing technology provided by the invention also has the following subsidiary technical features:
  • the mass m of the tap hammer is determined by the following formula.
  • A is the total coefficient of the aggregate aggregate aggregate particles, which is a constant, A ⁇ 1
  • ⁇ material is the density of synthetic aggregate mixed aggregate particles, the unit is kg/m 3 , a% is the proportion of synthetic aggregate mixed aggregate,
  • ⁇ agent is the density of the binder, the unit is kg / m 3 , b% is the proportion of the binder,
  • V is the volume of the synthetic stone mixture, the unit is m 3 ,
  • K is the mass coefficient of the slap weight, which is a constant, and K is 100-3000.
  • the total aggregate coefficient A of the composite aggregate aggregate aggregate is determined by the aggregate particle size, and as the aggregate particle size becomes smaller, the total aggregate coefficient of the synthetic aggregate aggregate aggregate aggregate becomes larger, and the synthetic stone bone having a particle diameter of less than 100 ⁇ m is obtained.
  • the coefficient of the aggregate is 0.8-1; the coefficient of the aggregate of the aggregate having a particle diameter of 100 ⁇ m to 1000 ⁇ m is 0.2-0.8; the coefficient of the aggregate of the aggregate having a particle diameter of 1000 ⁇ m or more is 0.04-0.2.
  • the total aggregate coefficient A of the synthetic aggregate aggregate aggregate is
  • A A 1 ⁇ R 1 %+A 2 ⁇ R 2 %+A 3 ⁇ R 3 %...+A n ⁇ R n %
  • a 1 , A 2 , A 3 ... A n are aggregate coefficients of different particle sizes, and R 1 , R 2 , R 3 , ... R n are ratios of aggregates having different particle diameters.
  • the utility model provides a hammer tapping synthetic stone forming machine and a processing technology according to the present invention, which has the following advantages compared with the prior art: the invention adopts a tapping weight with sufficient mass to directly shoot continuously under the driving of the driver. Strike the synthetic stone mixture on the base, the binder in the synthetic stone mixture flows during the slap, evenly distributed in the synthetic stone mixture, and forms a high-strength, high-density synthetic stone plate, a large number Reduces the amount of binder required in the original synthetic stone production technology.
  • the invention has the advantages of simple structure, stable operation, convenient maintenance and fast production speed, and can fully meet the needs of continuous large-scale production.
  • the synthetic stone processing technology provided by the invention adopts the heavy hammer slap-type pressing synthetic stone plate, which is a brand-new process, which is different from the pressure+vibration process in the prior art, improves the forming speed of the plate, and increases the production line. Production, reducing production costs.
  • Fig. 1 is a front view of the present invention.
  • Figure 2 is a top plan view of the present invention with the weight plate removed.
  • Figure 3 is a perspective view of the present invention.
  • Figure 4 is a cross-sectional view showing a first embodiment of the present invention.
  • Figure 5 is a cross-sectional view showing a second embodiment of the present invention.
  • Figure 6 is a cross-sectional view showing a third embodiment of the present invention.
  • Figure 7 is a cross-sectional view showing a fourth embodiment of the present invention.
  • an embodiment of a weight tapping synthetic stone forming machine includes a base 1, a weight 10 mounted on the base 1 and driving the weight
  • the driver 4 of the hammer 10 has a loading zone on the base 1, and the weight 10 slaps the loading zone.
  • the weight of the present invention has a sufficiently large weight to directly slap the synthetic stone mixture on the loading zone to photograph the synthetic stone mixture.
  • the "heavy hammer slap type" of the present invention is completely different from the “pressure + vibration” synthetic stone forming method in the prior art, and the present invention overcomes the "false pressure” problem existing in the prior art, and makes the “slap”
  • the binder in the synthetic stone mixture flows evenly in the synthetic stone mixture, fully filling the voids between the granular aggregates in the synthetic stone mixture, and the excess binder will be shot out of the synthetic stone mixture. Outside the material, the synthetic stone mixture is compacted.
  • the weight 10 includes a hammer plate 2 in contact with a synthetic stone mixture in the loading zone and is located on the hammer plate 2 and A weight-increasing weight plate 3 is added, which is connected to the hammer plate 2.
  • the invention provides a composite weight structure of the hammer plate 2 and the load plate 3, thereby constituting a stand-alone weight slap unit of the pressureless system, and the above-mentioned structure satisfies the slap force required for the molding of the synthetic stone.
  • the invention not only saves the pressure system, solves the problem of the virtual pressure, but also shortens the molding time of the synthetic stone.
  • the hammerless slap unit of the hydraulic system of the present invention consisting of the hammer plate 2 and the load plate 3 is different from the synthetic stone forming machine with a pressure system commonly used in the prior art.
  • the hammer plate 2 and the load plate 3 in the present invention may be a split structure or a one-piece structure, wherein the hammer plate 2 is mainly used for pressing a part of the synthetic stone mixture, and the weight plate 3 is provided with a load, which is increased. Slap force.
  • the structure of this portion is much larger than that of the hammer plate 2, so as to satisfy the slap force required for pressing.
  • the hammer plate 2 is provided with a plurality of supports 21, and the hammer plate 2 is connected to the load plate 3 through the support 21.
  • the support 21 is composed of an upper and lower horizontal plate and a plurality of vertical plates connecting the upper and lower horizontal plates.
  • the support 21 is four, respectively located at four corners of the hammer plate 2, thereby supporting the support.
  • the load plate 3 forms a cavity structure.
  • the support 21 of the present invention has a high supporting force so as to be able to meet the needs of the support.
  • the load-bearing plate 3 is formed by laminating a plurality of load-bearing plates 31.
  • the multi-layer load plates 31 are joined together by bolts.
  • the load-bearing sheet of the present invention may be made of solid steel or other heavier materials.
  • the pressure in the present invention is all provided by the weight plate 3, so that it has a large weight, and the above materials and structures can provide a sufficiently large slamming force.
  • the adjustment of the weight of the weight is achieved by adjusting the number of load plates 31.
  • the load-bearing plate 31 of the present invention may also be a one-layer structure.
  • the hammer plate 2 is further provided with a mold frame 22, and a periphery of the mold frame 22 is mounted with a suspension member 23, and the suspension member 23 is hooked. Hanging on the hammer plate 2.
  • the mold frame 22 is for restricting the surrounding synthetic stone mixture, the hammer plate 2 is pressed down along the mold frame 22, and the hanging member 23 is used for connecting the mold frame 22 and the hammer plate 2, when the hammer plate 2 is lifted. , the mold frame 22 is lifted together.
  • the base 1 is provided with a lifting device 11 which is connected to the weight 10.
  • the embodiment is connected to the load plate 3, the lifting device 11 is a hydraulic cylinder, and a part of the structure of the load plate 3 extends outward to form a support ear, and the lifting device 11 is connected to the support ear. Thereby, the lifting device 11 is facilitated to lift the load plate 3 and the hammer plate 2.
  • the actuator 4 is disposed on the weight 10, and the driver 4 is constructed by a plurality of drivers being synchronously connected together.
  • a plurality of the drives are synchronously coupled together to form a set of synchronous drive groups, and the weight 10 is provided with at least one set of synchronous drive groups.
  • the driver 4 is capable of generating a force greater than the weight of the weight, thereby lifting and taking the weight, and driving the weight 10 to slap the synthetic stone mixture at a certain speed.
  • the driver 4 in the present invention may also be in other structural forms, such as a driving device disposed outside the weight, so that the weight is reciprocated up and down to achieve a slap.
  • the present invention synchronizes the drives into multiple sets of forms that provide a sufficiently large lifting force to drive the weight.
  • a cavity is formed between the hammer plate 2 and the load plate 3, and the driver 4 is mounted in the cavity.
  • the cavity provides a mounting space for the drive 4, which of course can also be formed by a multi-layer load plate 3.
  • the synchronous driving groups are arranged in the same layer or in a layered arrangement.
  • the synchronous drive set is mounted on the hammer plate and/or on the load plate.
  • Figure 4 is a first embodiment of the same layer distribution, a total of four groups, wherein each group in the middle is four drives in series, two sets of two sets of two drives in series.
  • the driver in the present invention may also be arranged in a layered manner.
  • the driver 4 is placed on top of the load plate 3.
  • the driver in the present invention is one or more of a vibration motor, a hydraulic drive, an air drive, or an electromagnetic drive.
  • Figure 7 is a fourth embodiment of the present invention, which differs from the above embodiment in that the width or length of the load plate 3 is greater than the width or length of the hammer plate, and the partial load plate 3 is located on the side of the hammer plate 2.
  • the base 1 is a layer of load-bearing plate 15 or is laminated by a plurality of load-bearing plates 15, and the weight of the base 1 is greater than
  • the pulling force generated instantaneously by the driver 4 is described.
  • the pedestal of the present invention adopts a plate structure, and the contact with the foundation is more stable and is less likely to be displaced.
  • the susceptor 1 has a relatively large volume and weight, and can generate a large gravity, which is greater than a momentary force generated by the driver 4, so that the driver 4 cannot pull the susceptor 1, so that the susceptor 1 does not vibrate, thereby Solving the problem that the vibration of the pedestal weakens the slap force of the material, most of the slap force generated by the driver 4 acts on the material, which improves the forming effect and saves energy.
  • the plurality of the load-bearing plates 15 are connected by a bolt 16 into a unitary structure, and the base 1 of the present invention is a unitary structure, and therefore, the driver 4 will not drive some of the structural vibration.
  • the bottom surface of the bottom layer of the load-bearing plate is wholly or mostly in contact with the foundation, and the bottom of the base 1 is in contact with the foundation as much as possible, so that the base 1 is more stable and less prone to displacement.
  • the base 1 is stabilized so that the slamming force of the weight 10 acts on the material as much as possible.
  • the bottom layer of the load-bearing plate 15 is outwardly extended to form a connecting portion 151.
  • the connecting portion 151 is provided with a plurality of through holes 17 adapted to be connected with the foundation.
  • the foundation in the present invention adopts a concrete pouring structure and is surrounded by a concrete pouring structure.
  • a vibration isolating belt is provided, and a foundation is provided on the foundation, and the base 1 is connected to the foundation by bolts. Further, the base is less likely to be displaced.
  • the load bearing plate 15 of the uppermost layer is provided with the loading zone, and the loading zone is provided with a protective layer 18.
  • the protective layer 18 acts to protect the material carrier tape that passes through.
  • a heavy hammer tapping synthetic stone processing process includes the following steps:
  • A the ingredients, the synthetic stone mixed aggregate, the filler and the binder are mixed according to the ratio to form a synthetic stone mixture
  • the mass m of the tapping weight is determined by the following formula.
  • A is the total coefficient of the aggregate aggregate aggregate particles, which is a constant, A ⁇ 1
  • ⁇ material is the density of synthetic aggregate mixed aggregate particles, the unit is kg/m 3 , a% is the proportion of synthetic aggregate mixed aggregate,
  • ⁇ agent is the density of the binder, the unit is kg / m 3 , b% is the proportion of the binder,
  • V is the volume of the synthetic stone mixture, the unit is m 3 ,
  • K is the mass coefficient of the slap weight, which is a constant, and K is 100-3000. It is preferably 800-3000. The value is 1500 or 2000. The value of K is determined empirically according to the type of material, and is usually 1500.
  • the total particle size of the synthetic aggregate aggregate aggregate is determined by the aggregate particle size, and as the aggregate particle size becomes smaller, the total aggregate coefficient of the synthetic aggregate aggregate aggregate becomes larger, and the total aggregate coefficient A of the synthetic aggregate aggregate aggregate is determined by The aggregate particle size is determined, and as the aggregate particle size becomes smaller, the total aggregate coefficient of the synthetic aggregate aggregate aggregate becomes larger, wherein the composite aggregate coefficient of particle diameter less than 100 ⁇ m is 0.8-1; the particle size is 100 The micron-1000 micron synthetic aggregate coefficient is 0.2-0.8; the synthetic stone aggregate coefficient of 1000 micron or more is 0.04-0.2.
  • the total amount of synthetic stone mixed aggregate particles in the present invention is used for the amount of the aggregate in the unit volume. If the quantity is larger, the larger the moving force required for the aggregate, the more the hammer slamming force needs to be. Big.
  • the above aggregate coefficient is determined empirically based on the size of the overall particle size.
  • A A 1 ⁇ R 1 %+A 2 ⁇ R 2 %+A 3 ⁇ R 3 %...+A n ⁇ R n %
  • a 1 , A 2 , A 3 ... A n are aggregate coefficients of different particle sizes, and R 1 , R 2 , R 3 , ... R n are ratios of aggregates having different particle diameters.
  • quartzite is taken as an example.
  • the particle size of the material generally used includes: 13 ⁇ m, 18 ⁇ m, 23 ⁇ m, 38 ⁇ m, 45 ⁇ m, 58 ⁇ m, 109 ⁇ m, 212 ⁇ m, 380 ⁇ m, 830 ⁇ m. 1,700 ⁇ m, 3350 ⁇ m, 4750 ⁇ m, 8000 ⁇ m.
  • the aggregate coefficient of the minimum particle size of 13 ⁇ m is determined to be 1, and the aggregate coefficients of other particle diameters are 0.99, 0.98, 0.95, 0.91, 0.99, 0.79, 0.68, 0.58, respectively. , 0.30, 0.15, 0.12, 0.08, 0.05.
  • the weight can meet the molding needs of the sheet and be made into a sheet.
  • the weight of the weight of the synthetic stone plate which is 1 cm thick, 1 m wide and 1 m long is required to be 1 ton to 35 ton.
  • the specific values are determined according to factors such as the shape of the sheet, the thickness, the type of the material, and the particle size of the material.
  • the corresponding technical features of the weight determined by the present invention in the process examples are also applicable to the embodiment of the forming machine.

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)

Abstract

一种重锤拍击式合成石成型机，包括基座（1）、安装在基座（1）上的重锤（10）和驱动重锤（10）的驱动器（4），基座（1）上具有载料区，重锤（10）拍击载料区。同时还提供一种重锤拍击式合成石加工工艺，包括如下步骤：A、配料；B、布料；C、成型；D、固化。可形成高强度、高密度合成石板材。

Description

一种重锤拍击式合成石成型机及加工工艺 技术领域
本发明涉及一种合成石成型设备和加工工艺，尤其涉及一种无需压力系统的重锤拍击式合成石成型设备和加工工艺。
背景技术
天然石材作为建筑材料的重要部分，因为其色彩多样化，开发容易，自古以来一直被人广泛使用。但是随着其开采量的过度增加，开采利用率低等原因，天然石材的开采逐步受到限制，特别是欧洲国家，已经禁止了天然石材的开采。而且每个矿产区的产品，其花色，品种都是独一的，更增加了其使用上的难度。人们一直在寻找其替代品。随着经济的发展，建筑装饰材料日新月异，合成石作为一种新型的装饰材料得到很大的发展机遇。但由于其生产设备的加压系统和振动系统配合使用是一技术难题，致使设备制造复杂、生产运行不稳定、维护返修率高，生产效率无法达到规模化。如中国专利号为CN201120319813.9的实用新型专利，公开了一种人造石英石压机，包括机座、安装在机座两侧的机架、安装在机座底部的减震弹簧、安装于机座上的围框及冲头，所述的机座上设置有导柱，围框及冲头上设置有轴套，围框及冲头通过轴套活动连接于导柱上，导柱的上端固接有机顶，机顶上设置有冲头液压缸及围框液压缸，冲头液压缸通过液压缸连接座连接于冲头上，围框液压缸通过液压缸连接座连接于围框上，围框的底部及与冲头连接部位设置有真空密封条，冲头上设置有振动电机；机架及机座上方设置有传动带，传动带的两端设置有传动轮。在上述技术方案中，通过液压施加压力，再由振动电机进行振动，但这种压板方式存在如下缺点，由于振动电机是高频振动的工作，致使液压系统始终处于加压和释放的循环过程中，液压一直处于虚压状态，无法对板材施加足够的压力。同时，振动系统对整机的稳定性造成持久连续的伤害。为了满足板材成形，需要浪费大量的时 间。以上技术方案可以称为“压+振”的合成方式，整个行业一直所要解决的问题就是如何将压力和振动力复合在一起，但这个问题一直无法解决，严重影响了合成石成型设备的发展，始终缺少一种成熟、大规模应用、成型速度快的合成石成型设备和工艺。
发明内容
本发明所要解决的技术问题在于克服上述现有技术之不足，提供一种具有较高合成力、成型速度快、致密性好、结构简单的重锤拍击式合成石成型机，同时提供一种在真空状态下对疏松合成石混合料进行重锤拍击成为板材的加工工艺。
按照本发明提供的一种重锤拍击式合成石成型机，包括基座、安装在所述基座上的重锤和驱动所述重锤的驱动器，所述基座上具有载料区，所述重锤拍击所述载料区。
按照本发明提供的一种重锤拍击式合成石成型机还具有如下附属技术特征：
所述重锤包括与所述载料区中合成石混合料相接触的锤板和位于所述锤板上并增加重量的负重板，所述负重板与所述锤板连接在一起。
所述锤板上设置有多个支座，所述锤板通过所述支座与所述负重板连接在一起。
所述负重板由多层负重板材叠合而成。
所述锤板上还设置有一模框，所述模框的周边安装有悬挂件，所述悬挂件钩挂在所述锤板上。
所述基座上设置有抬升装置，所述抬升装置与所述重锤相连接。
所述驱动器设置在所述重锤上，所述驱动器由多台驱动器同步连接在一起构成。
多台所述驱动器同步连接在一起，构成一组同步驱动组，所述重锤上设置有至少一组同步驱动组。
所述同步驱动组同层布置或分层布置。
所述驱动器安装在所述锤板上和/或负重板上。
按照本发明提供的一种重锤拍击式合成石加工工艺，包括如下步骤：
A、配料，将合成石混合骨料、填充物和粘合剂按照配比混合，形成合成石混合料；
B、布料，将合成石混合料按照所需厚度平整的布置在输料带上或模框内；
C、成型，对合成石混合料进行排气真空处理，真空排气后由拍击重锤连续拍击合成石混合料，合成石混合料中的粘合剂在拍击的过程中流动，均匀的分布在合成石混合料中，充分填充合成石混合料中颗粒骨料之间的空隙，多余的粘合剂将会被拍击出合成石混合料外，直至形成致密的合成石板材；
D、固化，对成型的合成石板材进行固化，得到成品。
本发明提供的一种重锤拍击式合成石加工工艺还具有如下附属技术特征：
拍击重锤的质量m由下列公式确定，
m＝A×(ρ料×a％+ρ剂×b％)×V×K
其中，A为合成石混合骨料颗粒总量系数，为常数，A≤1，
ρ料为合成石混合骨料颗粒密度，单位为kg/m3，a％为合成石混合骨料所占比例，
ρ剂为粘合剂密度，单位为kg/m3，b％为粘合剂所占比例，
V为合成石混合料的体积，单位为m3，
K为拍击重锤的质量系数，为常数，K取值为100-3000。
合成石混合骨料颗粒总量系数A由骨料粒径确定，并随着骨料的粒径变小，合成石混合骨料颗粒总量系数变大，其中粒径小于100微米的合成石骨料系数为0.8-1；粒径为100微米-1000微米的合成石骨料系数为0.2-0.8；粒径为1000微米以上的合成石骨料系数为0.04-0.2。
合成石混合骨料颗粒总量系数A为，
A＝A1×R1％+A2×R2％+A3×R3％......+An×Rn％
其中，A1，A2，A3...An为不同粒径的骨料系数，R1，R2，R3，...Rn，为不同粒径的骨料所占比例。
按照本发明提供的一种重锤拍击式合成石成型机和加工工艺与现有技术相比具有如下优点：本发明采用具有具有足够大质量的拍击重锤在驱动器的带动下直接连续拍击位于基座上的合成石混合料，合成石混合料中的粘合剂在拍击的过程中流动，均匀的分布在合成石混合料中，并形成高强度、高密度合成石板材，大量减少了原有合成石生产技术中所需要的大量粘合剂。本发明具有结构简单、运行稳定、维护方便、生产速度快等优点，完全能满足持续大规模生产需要。本发明提供的合成石加工工艺采用重锤拍击式压制合成石板材，是一种全新的工艺，有别于现有技术中的压+振工艺，提高了板材的成型速度，增加了生产线的产量，降低生产成本。
附图说明
图1是本发明的主视图。
图2是本发明去掉负重板的俯视图。
图3是本发明的立体图。
图4是本发明第一实施例的剖视图。
图5是本发明第二实施例的剖视图。
图6是本发明第三实施例的剖视图。
图7是本发明第四实施例的剖视图。
具体实施方式
参见图1至图4，在本发明给出的一种重锤拍击式合成石成型机的实施例，包括基座1、安装在所述基座1上的重锤10和驱动所述重锤10的驱动器4，所述基座1上具有载料区，所述重锤10拍击所述载料区。本发明中的重锤具有足够大的重量，直接拍击载料区上的合成石混合料，将合成石混合料拍实。本发明这种“重锤拍击式”完全不同于现有技术中“压+振”的合成石成型方式，本发明克服了现有技术存在的“虚压”问题，通过“拍击”使得合成石混合料中的粘合剂流动，均匀的分布在合成石混合料中，充分填充合成石混合料中颗粒骨料之间的空隙，多余的粘合剂将会被拍击出合成石混合料外，从而压实合成石混合料。
参见图1至图4，在本发明给出的上述实施例中，所述重锤10包括与所述载料区中合成石混合料相接触的锤板2和位于所述锤板2上并增加重量的负重板3，所述负重板3与所述锤板2连接在一起。本发明设置了锤板2和负重板3的复合配重结构，从而构成了一个无压力系统的独立重锤拍击单元，通过上述结构满足合成石成型所需要的拍击力。本发明不仅省去了压力系统，解决了虚压的问题，而且能够缩短合成石的成型时间。本发明由锤板2和负重板3构成的无液压系统的重锤拍击单元，有别于现有技术中普遍采用的带压力系统的合成石成型机。
本发明中的锤板2和负重板3可以是分体式结构，也可以是一体式结构，其中锤板2主要是用于压制合成石混合料的部分，负重板3则是提供负重，增大拍击力。该部分的结构远远大于锤板2的结构，从而满足压制所需的拍击力。
参见图1至图4，在本发明给出的上述实施例中，所述锤板2上设置有多个支座21，所述锤板2通过所述支座21与所述负重板3连接在一起。所述支座21由上下横板和连接上下横板的多个竖板构成，本实施例所述支座21为四个，分别位于所述锤板2的四个角处，从而支撑所述负重板3，形成空腔结构。本发明中的支座21具有较高的支撑力，从而能够满足支撑的需要。
参见图1至图4，在本发明给出的上述实施例中，所述负重板3由多层负重板材31叠合而成。多层负重板材31通过螺栓连接在一起。本发明的负重板材可以采用实心钢板或其他较重的材料制成的板材。本发明中的压力均是由负重板3提供，因此其具有较大的重量，上述材料和结构能够提供足够大的拍击力。通过调节负重板材31的数量，实现对重锤重量的调节。当然，本发明中的负重板材31也可以是一层结构。
参见图1至图4，在本发明给出的上述实施例中，所述锤板2上还设置有一模框22，所述模框22的周边安装有悬挂件23，所述悬挂件23钩挂在所述锤板2上。所述模框22用于限制周边合成石混合料，所述锤板2沿所述模框22下压，所述悬挂件23用于连接模框22与锤板2，在锤板2提升时，带动模框22一起提升。
参见图1至图4，在本发明给出的上述实施例中，所述基座1上设置有抬升装置11，所述抬升装置11与所述重锤10相连接。本实施例与所述负重板3相连接，所述抬升装置11为液压缸，所述负重板3的部分结构向外延伸形成支撑耳，所述抬升装置11与支撑耳相连接。从而方便所述抬升装置11抬升所述负重板3和锤板2。
参见图1至图4，在本发明给出的上述实施例中，所述驱动器4设置在所述重锤10上，所述驱动器4由多台驱动器同步连接在一起构成。多台所述驱动器同步连接在一起，构成一组同步驱动组，所述重锤10上设置有至少一组同步驱动组。所述驱动器4能够产生大于重锤自重的力，从而将重锤抬起并拍下，按照一定的速度带动重锤10拍击合成石混合料。本发明中的驱动器4还可以为其他的结构形式，比如设置在重锤之外的驱动装置，使得重锤上下往复运动，实现拍击。本发明将驱动器同步为多组形式，能够提供足够大的抬升力，从而带动重锤。
参见图1至图4，在本发明给出的上述实施例中，所述锤板2与所述负重板3之间形成有空腔，所述驱动器4安装在所述空腔中。所述空腔为驱动器4提供了安装空间，当然，此空腔也可以是由多层负重板3形成。
参见图1至图4，在本发明给出的上述实施例中，所述同步驱动组同层布置或分层布置。所述同步驱动组安装在所述锤板上和/或负重板上。图4是第一种实施例为同层分布，共四组，其中中间每组为四台驱动器串联，两侧两组为两台驱动器串联。当然，本发明中的驱动器也可以是分层布置，例如，图5给出的第二实施例，在空腔中设置上下两组驱动器4。图6给出的第三实施例，在负重板3的顶部设置驱动器4。当然，也可以是同时设置在锤板2和负重板3上。本发明中的驱动器为振动电机、液压驱动器、空气驱动器或电磁驱动器中的一种或多种。
图7是本发明给出的第四实施例，其与上述实施例的主要差别在于，所述负重板3宽度或长度大于锤板的宽度或长度，部分负重板3位于锤板2的侧边，形成扁担式结构。这种结构能够降低设备的高度，方便设备的布置。
参见图1至图4，在本发明给出的上述实施例中，所述基座1为一层承重板材15或由多层承重板材15叠合而成，所述基座1的重力大于所述驱动器4瞬间产生的拉力。本发明中的基座采用板式结构，与地基的接触更加稳固，不易发生位移。所述基座1的体积和重量比较大，能够产生较大的重力，该重力大于驱动器4瞬间产生的拉力，使得驱动器4不能拉动基座1，也就使得基座1不会发生振动，从而解决基座振动削弱物料拍击力的问题，驱动器4产生的绝大部分拍击力作用于物料上，提高了成型效果，也节约了能源。例如本实施中驱动器4有12台，能够产生100吨的拉力，而基座1达到110吨，从而使得驱动器4无法带动基座1振动。
参见图1至图4，在本发明给出的上述实施例中，多层所述承重板材15通过螺栓16连接成整体式结构，本发明中的基座1为一个整体式结构，因此，驱动器4不会带动其中的部分结构振动。最底层的所述承重板材的底面全部或大部分与地基相接触，基座1的底部尽可能多的与地基接触，使得基座1更加稳固，不易发生位移。基座1稳定，使得重锤10的拍击力尽可能多的作用于物料上。最底层的所述承重板材15向外延长形成连接部151，所述连接部151上设置有多个适于与地基相连接的通孔17，本发明中的地基采用混凝土浇筑结构，其周围还设置有隔震带，地基上设置有连接件，基座1通过螺栓与所述地基连接在一起。进一步使基座不易发生位移。最上层的所述承重板材15上设置有所述载料区，所述载料区上设置有保护层18。所述保护层18对穿过的物料载料带起到保护的作用。
按照本发明提供的一种重锤拍击式合成石加工工艺，包括如下步骤：
A、配料，将合成石混合骨料、填充物和粘合剂按照配比混合，形成合成石混合料；
B、布料，将合成石混合料按照所需厚度平整的布置在输料带上或模框内；
C、成型，对合成石混合料进行排气真空处理，真空排气后由拍击重锤连续拍击合成石混合料，合成石混合料中的粘合剂在拍击的过程中流动，均匀的分布在合成石混合料中，充分填充合成石混合料中颗粒骨料 之间的空隙，多余的粘合剂将会被拍击出合成石混合料外，直至形成致密的合成石板材；
D、固化，对成型的合成石板材进行固化，得到成品。
在本发明给出的上述实施例中，拍击重锤的质量m由下列公式确定，
m＝A×(ρ料×a％+ρ剂×b％)×V×K
其中，A为合成石混合骨料颗粒总量系数，为常数，A≤1，
ρ料为合成石混合骨料颗粒密度，单位为kg/m3，a％为合成石混合骨料所占比例，
ρ剂为粘合剂密度，单位为kg/m3，b％为粘合剂所占比例，
V为合成石混合料的体积，单位为m3，
K为拍击重锤的质量系数，为常数，K取值为100-3000。优选为800-3000。取值为1500或2000。K的取值根据物料的种类依经验来确定，通常取值为1500即可。
合成石混合骨料颗粒总量系数由骨料粒径确定，并随着骨料的粒径变小，合成石混合骨料颗粒总量系数变大，合成石混合骨料颗粒总量系数A由骨料粒径确定，并随着骨料的粒径变小，合成石混合骨料颗粒总量系数变大，其中粒径小于100微米的合成石骨料系数为0.8-1；粒径为100微米-1000微米的合成石骨料系数为0.2-0.8；粒径为1000微米以上的合成石骨料系数为0.04-0.2。本发明中的合成石混合骨料颗粒总量系数是用于反应骨料在单位体积中的数量，如果数量越多，则说明骨料需要的移动力越大，重锤拍击力也就需要越大。上述骨料系数根据总体粒径的大小依经验来确定。
合成石混合骨料颗粒总量系数A，
A＝A1×R1％+A2×R2％+A3×R3％......+An×Rn％
其中，A1，A2，A3...An为不同粒径的骨料系数，R1，R2，R3，...Rn，为不同粒径的骨料所占比例。
本实施例以石英石为例，石英石的密度为ρ料＝2600kg/cm3，通常所用的物料颗粒粒径包括：13μm，18μm，23μm，38μm，45μm，58μm，109μm，212μm，380μm，830μm，1700μm，3350μm，4750μm，8000μm，根据经验， 首先确定最小粒径13μm的骨料系数为1，则其他粒径的骨料系数依次为0.99、0.98、0.95、0.91、0.89、0.79、0.68、0.58、0.30、0.15、0.12、0.08、0.05。
压制长度为1m、宽度为1m和高度为0.01m的合成石石英板材，其中骨料的总量为a％＝91％，粒径为38μm的石英石占30％、粒径为109μm的石英石占20％、粒径为212μm的石英石占20％、粒径为380μm的石英石占21％，粘合剂的密度为ρ剂＝1130kg/m3，占总量的比例为b％＝9％。
则A＝0.95×30％+0.79×20％+0.68×20％+0.58×21％
＝0.285+0.158+0.136+0.1218＝0.7008
重锤的质量则为m＝0.7008×(2600×91％+1130×9％)×0.01×1500
＝25940.46kg
重锤按照上述重量配置就能够满足板材的成型需要，制成板材。本发明在选取经验值时，原则上需要满足压制1cm厚度、1m宽、1m长的合成石板材的重锤质量为1吨至35吨。具体数值依据板材形状、厚度、物料种类、物料颗粒度等因素来确定。本发明在工艺实施例中确定的重锤相应技术特征，也适用于成型机的实施例中。

Claims (16)

  1. 一种重锤拍击式合成石加工工艺，包括如下步骤：
    A、配料，将合成石混合骨料、填充物和粘合剂按照配比混合，形成合成石混合料；
    B、布料，将合成石混合料按照所需厚度平整的布置在输料带上或模框内；
    C、成型，对合成石混合料进行排气真空处理，真空排气后由拍击重锤连续拍击合成石混合料，合成石混合料中的粘合剂在拍击的过程中流动，均匀的分布在合成石混合料中，充分填充合成石混合料中颗粒骨料之间的空隙，多余的粘合剂将会被拍击出合成石混合料外，直至形成致密的合成石板材；
    D、固化，对成型的合成石板材进行固化，得到成品。
  2. 如权利要求1所述的一种重锤拍击式合成石加工工艺，其特征在于：拍击重锤的质量m由下列公式确定，
    m＝A×(ρ料×a％+ρ剂×b％)×V×K
    其中，A为合成石混合骨料颗粒总量系数，为常数，A≤1，
    ρ料为合成石混合骨料颗粒密度，单位为kg/m3，a％为合成石混合骨料所占比例，
    ρ剂为粘合剂密度，单位为kg/m3，b％为粘合剂所占比例，
    V为合成石混合料的体积，单位为m3，
    K为拍击重锤的质量系数，为常数，K取值为100-3000。
  3. 如权利要求2所述的一种重锤拍击式合成石加工工艺，其特征在于：合成石混合骨料颗粒总量系数A由骨料粒径确定，并随着骨料的粒径 变小，合成石混合骨料颗粒总量系数变大，其中粒径小于100微米的合成石骨料系数为0.8-1；粒径为100微米-1000微米的合成石骨料系数为0.2-0.8；粒径为1000微米以上的合成石骨料系数为0.04-0.2。
  4. 如权利要求2所述的一种重锤拍击式合成石加工工艺，其特征在于：合成石混合骨料颗粒总量系数A，
    A＝A1×R1％+A2×R2％+A3×R3％......+An×Rn％
    其中，A1，A2，A3...An为不同粒径的骨料系数，R1，R2，R3，...Rn，为不同粒径的骨料所占比例。
  5. 一种重锤拍击式合成石成型机，其特征在于：包括基座、安装在所述基座上的重锤和驱动所述重锤的驱动器，所述基座上具有载料区，所述重锤拍击所述载料区。
  6. 如权利要求5所述的一种重锤拍击式合成石成型机，其特征在于：所述重锤包括与所述载料区中合成石混合料相接触的锤板和位于所述锤板上并增加重量的负重板，所述负重板与所述锤板连接在一起。
  7. 如权利要求6所述的一种重锤拍击式合成石成型机，其特征在于：所述锤板上设置有多个支座，所述锤板通过所述支座与所述负重板连接在一起。
  8. 如权利要求6所述的一种重锤拍击式合成石成型机，其特征在于：所述负重板由多层负重板材叠合而成。
  9. 如权利要求6所述的一种重锤拍击式合成石成型机，其特征在于：所述锤板上还设置有一模框，所述模框的周边安装有悬挂件，所述悬挂件钩挂在所述锤板上。
  10. 如权利要求5所述的一种重锤拍击式合成石成型机，其特征在于：所述基座上设置有抬升装置，所述抬升装置与所述重锤相连接。
  11. 如权利要求5所述的一种重锤拍击式合成石成型机，其特征在于：所述驱动器设置在所述重锤上，所述驱动器由多台驱动器同步连接在一起构成。
  12. 如权利要求11所述的一种重锤拍击式合成石成型机，其特征在于：多台所述驱动器同步连接在一起，构成一组同步驱动组，所述重锤上设置有至少一组同步驱动组。
  13. 如权利要求12所述的一种重锤拍击式合成石成型机，其特征在于：所述同步驱动组同层布置或分层布置。
  14. 如权利要求6所述的一种重锤拍击式合成石成型机，其特征在于：所述驱动器安装在所述锤板上和/或负重板上。
  15. 如权利要求5所述的一种重锤拍击式合成石成型机，其特征在于：所述基座为一层承重板材或由多层承重板材叠合而成，所述基座的重力大于所述驱动器瞬间产生的拉力。
  16. 如权利要求15所述的一种重锤拍击式合成石成型机，其特征在于：多层所述承重板材通过螺栓连接成整体式结构，最底层的所述承重板材的底面全部或大部分与地基相接触，最底层的所述承重板材向外延长形成连接部，所述连接部上设置有多个适于与地基相连接的通孔，最上层的所述承重板材上设置有所述载料区，所述载料区上设置有保护层。
PCT/CN2015/087371 2015-01-20 2015-08-18 一种重锤拍击式合成石成型机及加工工艺 Ceased WO2016115884A1 (zh)

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