Technical Field

The present invention relates to a piece of equipment for the manufacture of slabs of ceramic and/or stone material.

Background Art

It is well known that the need is particularly felt, in many sectors of industrial activities, to renew the manufactured products and to search for new ones in order to better distinguish them from those of competitors.

This need is felt, in particular, in the industry that deals with the production of slabs made of ceramic and/or stone material used for the manufacture, e.g., of floors and/or walls.

Today the market requires more and more special aesthetic effects, such as e.g. the reproduction of natural rocks, such as marble or granite, characterized by the presence of “veins”, i.e. streaks of different color compared to the basic material, having an irregular pattern and crossing the entire thickness thereof. The manufacture of slabs made of ceramic and/or stone material, such as slabs made of mineral grits bound with resins, generally involves a phase of deposition of a basic material, which may consist of ceramic materials or of a mixture of mineral compounds in granular form (e.g. marble, granite), glass, mirror fragments, quartz powder, etc., as well as resins which act as binders, on a supporting surface, such as a belt or a mould, to form a slab to be compacted, and a subsequent phase of pressing, so as to obtain a compacted slab.

Depending on the type of mixture, further phases are then carried out, such as e.g. firing and subsequent cooling, in order to obtain a product with special mechanical and physical properties.

The equipment needed to carry out these phases therefore requires the presence of dispensing means of the basic material on a supporting surface, so as to form a slab to be compacted, and pressing means to obtain a compacted slab.

As known to the technician in the sector, depending on the type of materials used, the embodiments and the technical characteristics of the devices that make up the relevant equipment may vary.

A known type of equipment involves the use of a hopper which extends for the entire width of the slab to be obtained and inside which are loaded the ceramic materials to be deposited on an extraction surface, a relevant movement being provided between the latter and the hopper itself.

In order to obtain special chromatic effects, such as e.g. a “veined” effect, a plurality of materials of different types are deposited inside the hopper, which stratify inside the hopper and are then deposited in succession on the extraction surface.

Due to the friction of the material on the walls of the hopper, the flow of the material outside the hopper is not even and random, so the intensity of the color of the veins obtained is shaded or inaccurate.

Furthermore, the ceramic material coming out of the hopper, coming into contact with the terminal portion of the walls, is partly dragged on the surface of the slab with a consequent alteration of the desired aesthetic effect.

Last but not least, the slabs thus obtained have “longitudinal” veins with respect to the surface of the slab, i.e. they do not pass through the entire thickness thereof. This drawback therefore prevents obtaining a so-called “passing through vein”, typical of natural rocks, which is particularly evident when slabs have to be made with two orthogonal surfaces, as in the case of tops for kitchens, bathrooms or other similar applications, so it is not possible to obtain a substantially continuous vein along the two orthogonal surfaces.

Description of the Invention

The main aim of the present invention is to devise a piece of equipment for the manufacture of slabs of ceramic and/or stone material that allows obtaining a wide variety of aesthetic effects in a simple and reliable manner.

Another object of the present invention is to devise a piece of equipment for the manufacture of slabs of ceramic and/or stone material that allows reducing the friction effect of the walls of the hopper on the deposition of the material on the extraction surface and that allows dispensing the material contained therein in a way that is reproducible over time as much as possible. A further object of the present invention is to devise a piece of equipment for the manufacture of slabs of ceramic and/or stone material that allows obtaining slabs that reproduce as faithfully as possible the chromatic effect of natural rocks.

Another object of the present invention is to devise a piece of equipment for the manufacture of slabs of ceramic and/or stone material that allows overcoming the aforementioned drawbacks of the prior art in a simple, rational, easy, effective to use and low-cost solution.

The objects set out above are achieved by the present equipment for the manufacture of slabs of ceramic and/or stone material having the characteristics of claim 1.

Brief Description of the Drawings

Other characteristics and advantages of the present invention will be more evident from the description of a preferred, but not exclusive, embodiment of a piece of equipment for the manufacture of slabs of ceramic and/or stone material, illustrated by way of an indicative, yet non-limiting example, in the attached tables of drawings in which:

Figure 1 is an axonometric view of the equipment for the manufacture of slabs of ceramic and/or stone material according to the invention;

Figure 2 is a sectional side view of an embodiment of the equipment according to the invention;

Figure 3 is a sectional side view of a further embodiment of the equipment according to the invention;

Figure 4 is a side view of a component of the equipment according to the invention;

Figure 5 is a rear view of the equipment according to the invention. Embodiments of the Invention

With particular reference to these figures, reference numeral 1 globally indicates a piece of equipment for the manufacture of slabs of ceramic and/or stone material.

The equipment 1 comprises at least one hopper 2 defining a containment chamber 3 of ceramic and/or stone materials M and provided with at least one inlet port 3a and with at least one outlet port 3b opposite each other.

In the context of the present treatise, the expression “ceramic and/or stone materials” means materials of the ceramic type, in the form of atomized particles, grains or flakes, and/or of the stone type, such as marble, granite, minerals or other natural stones, in the form of powder and/or granulate and/or flakes and mixed with a binder of a cement nature or resins.

The equipment 1 is also provided with dispensing means 4 of a plurality of ceramic and/or stone materials M of different type and/or color inside the containment chamber 3 through the inlet port 3 a.

The dispensing means 4 comprise one or more dispensing devices 5 adapted to deposit above a dispensing surface 6 the different types of ceramic and/or stone materials M.

In the embodiment shown in the figures, the dispensing surface 6, of the type of a conveyor belt or the like, is movable along a direction of flow Dl, in order to transport the ceramic and/or stone materials M towards the inlet port 3a of the hopper 2.

The dispensing devices 5 comprise a relevant container movable along a direction transverse to the direction of flow Dl in order to deposit the ceramic and/or stone materials M by the entire width extension of the dispensing surface

6.

Additional embodiments cannot however be ruled out wherein the ceramic and/or stone materials M are manually deposited by an operator on top of the dispensing surface 6, or wherein the ceramic and/or stone materials M are manually loaded into the hopper 2.

The equipment 1 comprises at least one extraction surface 7 of the ceramic and/or stone materials M contained in the containment chamber 3, located below the outlet port 3b and movable along a direction of forward movement D2.

The extraction surface 7 is of the type of a conveyor belt or the like.

More in detail, the dispensing surface 6 and the extraction surface 7 are positioned on two separate planes, substantially parallel to each other and arranged at a distance equal to the extension in height of the hopper 2.

The direction of forward movement D2 is substantially parallel to the direction of flow D1 of the dispensing surface 6.

The extraction surface 7 by flowing along the direction of forward movement D2, drags the ceramic and/or stone materials M away from the hopper 2, taking them from the outlet port 3b.

This way, the ceramic and/or stone materials M, stratified inside the containment chamber 3, are deposited in succession on the extraction surface 7 to form a slab to be compacted L, which is then directed towards additional machining devices to be subjected to subsequent manufacturing phases. According to the invention, the hopper 2 comprises at least two walls 8,9 partly delimiting the containment chamber 3, positioned in succession along the direction of forward movement D2 and tilted with respect thereto. Advantageously, the walls 8,9 comprise a lower wall 8 and an upper wall 9, opposite each other, where the lower wall 8 is positioned upstream of the upper wall 9 relative to the direction of forward movement D2.

The lower wall 8 and the upper wall 9 are substantially parallel to each other. The containment chamber 3 is further delimited by a pair of lateral walls 10 opposite and parallel to each other, and arranged transversely to the walls 8,9. The special tilting arrangement of the walls 8,9 causes the ceramic and/or stone materials M, transported by the dispensing surface 6 towards the inlet port 3a, to fall by gravity inside the containment chamber 3 and to rest on the lower wall 8. In doing so, the ceramic and/or stone materials M flow towards the outlet port 3b and contact the lower wall 8 only, so the upper wall 9 does not limit the flow of ceramic and/or stone materials outwards.

This way, the ceramic and/or stone materials M, as they are extracted from the hopper 2, descend inside the containment chamber 3 towards the outlet port 3b thus defining a series of layers arranged one on top of the other and tilted with respect to the extraction surface 7.

The ceramic and/or stone materials M are then extracted in sequence as a result of the forward movement of the extraction surface 7.

The slab to be compacted L which has been obtained reproduces, therefore, an extremely faithful effect and layering compared to those of natural rocks, such as e.g. marble and granite.

According to the invention, the walls 8,9 are also mutually movable to vary the shape of the containment chamber 3.

This particular feature allows varying the volume of the containment chamber 3 and the extension, in particular, of the outlet port 3b depending on the amount of material to be loaded inside the hopper 2, the type of layering and, therefore, the aesthetic effect to be obtained.

By increasing the volume of the containment chamber 3, during the extraction of the ceramic and/or stone materials M, it is possible, for example, to increase the output speed thereof.

In a first embodiment, shown in Figure 2, at least one of either the lower wall 8 or the upper wall 9 is movable in translation relative to the other along the direction of forward movement D2 so as to vary the distance between them.

In this embodiment, the shape of the containment chamber 3 remains substantially unchanged but the volume thereof is modified; the extension of the inlet port 3a and of the outlet port 3b remain coincident to each other. Appropriately, the equipment 1 comprises shifting means 11,12 for shifting at least one of the walls 8,9 along the direction of forward movement D2. Preferably, the upper wall 9 is movable in translation relative to the lower wall 8.

More in detail, the shifting means 11,12 comprise shifting guides 11 associated with the upper wall 9 and sliding pins 12 associated with the lateral walls 10 and movable sliding along the aforementioned shifting guides 11.

In a further embodiment, shown in Figure 3, at least one of either the lower wall 8 or the upper wall 9 is movable in rotation around an axis A transverse to the direction of forward movement D2 so as to vary the mutual inclination of the walls themselves.

In particular, the axis A is substantially parallel to the dispensing surface 6 and perpendicular to the direction of forward movement D2.

Conveniently, the upper wall 9 is movable in rotation around the axis A.

In the embodiment shown in Figure 3, the axis A passes through an intermediate area of the upper wall 9.

Alternative embodiments cannot however be ruled out wherein the axis A is arranged in a different area from that shown in Figure 3.

Again with reference to the present embodiment, as a result of the rotation of the upper wall 9 around the axis A, the shape of the containment chamber 3 varies and the inlet port 3a and the outlet port 3b take on different extensions.

In other words, the hopper 2 takes on the shape of a funnel in which, depending on the direction of rotation of the upper wall 9 around the axis A, the extension of the inlet port 3 a is smaller than the extension of the outlet port 3b and vice versa.

Advantageously, the upper wall 9 is provided with a terminal portion 9a delimiting the outlet port 3b and provided with a protrusion 13 adapted to contact the ceramic and/or stone materials M placed on the extraction surface 7 following the movement thereof along the direction of forward movement D2. The protrusion 13 is intended to carry out a leveling action on the ceramic and/or stone materials M coming out of the containment chamber 3 and the distance between the extraction surface 7 and the protrusion itself determines the thickness of the slab to be compacted L.

Preferably, the protrusion 13 is rounded in shape.

In particular, the protrusion 13 is shaped so as to define a substantially linear contact with the ceramic and/or stone materials M arranged on the extraction surface 7.

This way, the mutual contact between the terminal portion 9a and the ceramic and/or stone materials M is minimized and the aesthetic effect of the layering is preserved.

Advantageously, the equipment 1 comprises vibratory means 14 associated with the lower wall 8 and adapted to facilitate the flow of the ceramic and/or stone materials M towards the outlet port 3b. The vibration of the lower wall 8, on which the ceramic and/or stone materials M are placed, makes it easier for them to fall down and facilitate their outflow. Preferably, the vibratory means 14 comprise a plurality of vibrating elements 15 which can be operated independently of one another to define a preferential output path P of the ceramic and/or stone materials M.

As shown in Figure 5, in fact, the setting in vibration of only a few vibrating elements 15 causes the ceramic and/or stone materials M to be induced to follow the preferential output path P thus allowing “selecting” the order of outflow of the ceramic and/or stone materials M through the outlet port 3b. Appropriately, the equipment 1 is provided with a closing device 16 that can be moved to block at least part of the outlet port 3b.

The closing device 16 allows, therefore, interrupting or reducing the extraction of the ceramic and/or stone materials M from the hopper 2.

In particular, the closing device 16 comprises a shutter 17 associated with the lower wall 8 and movable along the direction of forward movement D2.

More in detail, the shutter 17 has a substantially sheet-shaped conformation and is positionable between the hopper 2, at the point where the outlet port 3b is located, and the extraction surface 7.

The shutter 17 slides on guidance elements 18 associated with the lower wall 8 and is operated by a hydraulic cylinder 19.

Conveniently, the closing device 16 comprises adjustment means for adjusting the speed of displacement of the shutter 17.

The adjustment means allow setting a speed of displacement of the shutter 17 in order to avoid a relevant movement with respect to the ceramic and/or stone materials M that are deposited on the extraction surface 7 and that would cause the deterioration of the chromatic composition obtained.

In other words, the adjustment means ensure that the shutter 17 does not exert a thrust action on the ceramic and/or stone materials M and does not alter, therefore, the surface composition thereof.

In addition, the adjustment means allow even partial obstruction of the outlet port 3b, so as to vary the outflow of the ceramic and/or stone materials M through the outlet port 3b, depending on the aesthetic effect to be given to the slab to be compacted L.

Advantageously, the equipment 1 comprises at least one electronic control unit operationally connected to the extraction surface 7 and to the adjustment means of the speed of the shutter 17.

The electronic control unit is able to detect the speed of forward movement of the extraction surface 7, the position of the shutter 17 and the speed of displacement thereof.

More in detail, the electronic control unit is programmed to operate the adjustment means in such a way that the speed of displacement of the shutter 17 is substantially equal to the speed of forward movement of the extraction surface 7.

The operation of the present invention is as follows.

The dispensing means 4 deposit a plurality of ceramic and/or stone materials M on the dispensing surface 6.

The latter, moving forward along the direction of flow Dl, transports the ceramic and/or stone materials M towards the inlet port 3a of the hopper 2.

The ceramic and/or stone materials M fall by gravity inside the containment chamber 3 resting on the lower wall 8 and positioning themselves in such a way as to define a plurality of tilted layers, overlapping each other.

The extraction surface 7, at the point where the outlet port 3b is located, sliding along the direction of forward movement D2, extracts the ceramic and/or stone materials M from the hopper 2 thus forming a slab to be compacted L.

The protrusion 13 of the terminal portion 9a of the upper wall 9 levels the ceramic and/or stone materials M without altering the aesthetic effect given by the layering of the ceramic and/or stone materials contained in the hopper 2. During the formation of the slab to be compacted L, the volume or shape of the containment chamber 3 can be changed by acting on the upper wall 9.

By shifting or rotating the upper wall 9 it is possible to vary the layering of the ceramic and/or stone materials and their speed of outflow from the hopper 2, in order to give the slab to be compacted a particular aesthetic effect. In addition, the vibratory means 14 can be activated to determine the preferential output path P of the ceramic and/or stone materials M contained inside the containment chamber 3.

The vibratory means 14 operate on the lower wall 8 to facilitate the flow of the ceramic and/or stone materials M downwards.

More in detail, the vibrating elements 15 are made to vibrate independently of each other to determine the preferential output path P. (Figure 5)

In order to carry out a partial extraction, or at the end of the extraction itself, the closing device 16 is operated to partly or totally obstruct the outlet port 3b. For this purpose, the shutter 17 is shifted along the direction of forward movement D2 to position itself between the hopper 2 and the extraction surface 7.

The electronic control unit communicates with the adjustment means to determine the speed of displacement of the shutter 17 suitable for partial or total closure of the outlet port 3b.

It has in practice been ascertained that the described invention achieves the intended objects and in particular the fact is underlined that the equipment for the manufacture of slabs of ceramic and/or stone material according to the present invention allows obtaining a wide variety of aesthetic effects in a simple and reliable way, thanks to the effective layering and extraction of the ceramic materials from the hopper.

The particular shape of the hopper and the mutual mobility of the walls reduce the effect of the friction on the deposition of the ceramic and/or stone materials and facilitate their outflow, thus allowing obtaining the desired aesthetic effect. Finally, the equipment for the manufacture of slabs of ceramic and/or stone material according to the invention allows obtaining slabs that faithfully reproduce the layering of the mineral compounds of natural rocks.