EP0429330B1 - Process and apparatus for making coloured decorative panels from exfoliated rocks particles - Google Patents

Process and apparatus for making coloured decorative panels from exfoliated rocks particles Download PDF

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Publication number
EP0429330B1
EP0429330B1 EP90403107A EP90403107A EP0429330B1 EP 0429330 B1 EP0429330 B1 EP 0429330B1 EP 90403107 A EP90403107 A EP 90403107A EP 90403107 A EP90403107 A EP 90403107A EP 0429330 B1 EP0429330 B1 EP 0429330B1
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EP
European Patent Office
Prior art keywords
colored
binder
layer
particles
distributor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP90403107A
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German (de)
French (fr)
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EP0429330A1 (en
Inventor
Roland Berion
Dominique Résidence les Clés de la Forêt Garnier
Claude Menard
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Efisol
Elf Isolation
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Efisol
Elf Isolation
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Publication of EP0429330A1 publication Critical patent/EP0429330A1/en
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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
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • 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
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/02—Conditioning the material prior to shaping
    • 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
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
    • B28B5/026—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length
    • B28B5/027—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed

Definitions

  • the present invention relates to a process and to an installation for the continuous manufacture of colored panels of particles or granules agglomerated by a binder and in particular of panels made up of particles of exfoliated rocks such as vermiculites.
  • the process described in this document is characterized in that at the same time as the concrete support layer, one or more layers of concrete are deposited on this layer constituting a visible surface; these layers are packed together.
  • the proposed device comprises a multilayer spreader distributor, constituted by a conveyor belt associated with at least two concrete distributors; each of these distributors is followed by a compression roller.
  • FR-A-2 286 085 an automatic machine for distributing bulk materials, on a road or a similar fixed support.
  • This machine comprises a chassis supporting a storage hopper and a dispensing member for the material to be dispensed; the chassis and driven by a relative translational movement relative to the receiving members.
  • the dispensing member consists of a substantially vertical column connected to the outlet of the hopper by an inclined plane. It is proposed to associate the hopper with two distribution columns, each cooperating with a different inclined plane, or even to use several hoppers for distributing different materials in layers.
  • a device for the continuous production of cement roof plates in which are arranged in series on a conveyor belt a hopper with a doctor blade adjustable in height, a leveling device , a profiled precompression roller, a press consisting of a hammer, ensuring a pressing and striking effect, perpendicular to the mass and in the direction of its movement, a color diffuser and finally a smoothing device.
  • the first two documents do not ensure sufficient compression of the layers obtained; these machines are very suitable for concrete, but do not make it possible to obtain panels of light particles, which must be dense and compressed to have sufficient rigidity and solidity.
  • the last document provides compression of the plates using a press located above the conveyor belt, which leads to a machine of fairly high structure.
  • the problem that the invention proposes to solve is to obtain a machine of the type described in document DE-A-1 815 973, which makes it possible to obtain dense, solid and rigid panels, with good compression of the panels. , while keeping the compression machine a fairly low structure.
  • the method according to the invention has many advantages over known methods.
  • the conduct of the continuous process allows perfect preparation of the materials while ensuring reproducibility of the characteristics of formation, composition and identical qualities of each panel produced.
  • the means of control and piloting of the installation offering all the guarantees of dosing of particles and binders, the continuous operation makes it possible to minimize the number of preparations to be stored by the implementation of small quantities adapted to the request, avoiding therefore significant storage.
  • the coloring of the panel is obtained by adding to the base layer impregnated with natural binder with a colored layer in the mass thanks to the use of the colored binder itself, which penetrates during the impregnation in the mass of treated particles and gives the panel thus obtained a constant coloration and durable.
  • the method according to the invention allows the constitution of panels in several layers, hence the possibility of applying different particle sizes and materials for each layer, as well as of varying the thicknesses and the number of layers.
  • the structure of the machine is lower than that of known machines.
  • the present invention therefore provides a process for manufacturing colored panels of mineral particles or granules agglomerated by a binder, in which a material resulting from the mixing of metered quantities of said particles and an inorganic binder is continuously deposited on a mobile formation surface.
  • the particles used are particles of exfoliated rocks, such as vermiculite, with a particle size of between 0.3 and 4 mm and that the binder is an alkali silicate having a viscosity of the around 350 mPa.
  • the coloring of the mass of the particles is carried out by imparting to the particles a vortex movement to disperse them within the sprayed colored binder.
  • the particle size of the particles used for the preparation of the colored layer is different from that of the particles of the other layers.
  • the mobile forming surface is constituted by a strip transport associated with at least two distributors of impregnated particles, of which the first distributor of non-colored particles is composed of a hopper whose bottom has two divergent planes whose common edge of the summit is located transversely to the direction of advance of the strip and whose spacings from the walls of the hopper constitute weirs, the lower edge of one of said planes located upstream relative to the edge of the summit constituting a threshold determining the level of a first layer coming from the first weir, while a height-adjustable hatch or strip placed downstream of the first distributor determines the thickness of a second layer coming from the second weir, a compression roller being placed downstream of each weir and of which the second distributor of colored impregnated particles placed downstream of the first is provided with means ensuring the crumbling of the mass and the leveling ment of the deposited layer.
  • the means ensuring the crumbling of the mass and the leveling of the upper layer consist of walls of the hopper placed in baffles and in a reel of distribution provided with blades rotating.
  • the levels of the strip of the first distributor and of the weir of the second distributor are controlled by an integrated system for adjusting the thicknesses of the upper layers.
  • the cake composed of the layers previously formed, is shaped by continuous pressing using an upper preforming plate adjustable by an articulation, driven in a movement vertical alternative by means of a crank articulated to an eccentric placed on a pulley, and driven in a synchronous oscillating horizontal movement.
  • a single motor drives in rotation by means of belts a kinematic assembly ensuring the oscillation of a movable table and the pulley actuating the crank of the press plate.
  • recirculation means are used for the colored binder obtained to ensure a desired constant temperature and good homogeneity of the colored binder.
  • the invention also relates to an installation for implementing the method of the invention, comprising units for preparing masses impregnated with binder, means for continuously transferring said masses to a multilayer spreader distributor, said distributor being constituted by a conveyor belt associated with at least two distributors of impregnated particles, a compression roller being placed downstream of at least one of said distributors, characterized in that the first distributor is a distributor of non-colored particles composed of a hopper , the bottom of which has two divergent planes, the common edge of the top of which is situated transversely to the direction of advancement of the strip and the spacings of the walls of the hopper of which constitute weirs, in that the lower edge of one of said planes located upstream relative to the edge of the summit constitutes a threshold determining the level of a first co uche from the first weir, while a height-adjustable hatch or strip placed downstream of the distributor determines the thickness of a second layer coming from the second weir, in that the second distributor is a distributor of colored imp
  • the levels of the strip of the first distributor and of the weir of the second distributor are controlled by an integrated system for adjusting the thicknesses of the upper layers.
  • said shaping machine by continuous pressing ensures continuous pressing of the cake composed of the layers previously formed, running on a forming surface, using an upper plate of preforming with an alternating vertical movement and fixed by an articulation on a movable table animated with a synchronous oscillating horizontal movement, said upper preforming plate being driven in an alternating vertical movement by means of a crank articulated to an eccentric placed on a pulley.
  • a single motor drives in rotation by means of belts a kinematic assembly ensuring the oscillation of the movable table and the pulley actuating the crank of the upper preforming plate.
  • one of said units for preparing masses impregnated with binder is a sub-unit for preparing colored binder which consists of a jacketed reactor equipped with an agitator, probes levels and pump transfer to a buffer tank and which is further provided with feed openings in metered quantities of binder, water and coloring matter.
  • the vermiculite used was obtained by exfoliation by thermal shock, then dusted and freed from all impurities, so as to have an apparent density and a constant particle size.
  • the binder is an alkaline silicate such as potassium silicate in liquid form, of specific density and viscosity. It is maintained at its operating temperature by continuous cycling and thermoregulation.
  • Fine particles of vermiculite are continuously admitted into silo 1, equipped with level probes, this silo constituting a buffer reserve sufficient for the proper functioning of the installation and allowing the overfilling which may come from a difference in the flow rates between exfoliation ovens and demand from the panel manufacturing facility.
  • the particles are taken up at the outlet of the silo 1 by a continuous transport and metering assembly using a flow limitation valve 2, a conveyor belt 3 continuously scrolling and a weighing system 4.
  • mixer 6 converge vermiculite and potassium silicate.
  • the vermiculite particles are coated by imparting a swirling motion to the particles and by dispersing them within the sprayed binder, for example in a mixer which is the subject of a patent application also filed today in the name of the depositor.
  • the flow rate and the pressure are provided by the metering pump 5.
  • the coated vermiculite is continuously taken up by the belt conveyor 7 to be screened on a vibrating screen 8 retaining the formation of accidental agglomerates and driving them to a recycling bin 9.
  • the coated vermiculite is taken up continuously by a conveyor belt made of non-stick material 10 with weighing control 11.
  • the purpose of the weighing control is to balance the materials and adjust the vermiculite flow in 2 and the silicate flow by the metering pump 5.
  • the coated vermiculite pours into the double hopper 12 of the multilayer spreader distributor to form the lower panel layer or the base layer.
  • the installation for preparing the colored layer presented in FIG. 1 is composed of the two preparation lines allowing the production of the two masses of different coloring intended to be mixed in order to obtain a two-color layer.
  • the vermiculite is metered by a flow limiting valve 14, and is controlled by a weighing system 16.
  • a flow limiting valve 14 In the mixers 17, 17a converge the vermiculite and potassium silicate previously colored, the preparation of which follows. (figure 2).
  • the preparation of the colored binder is preferably carried out in a reactor 71 with a heating jacket ensuring a constant temperature of use of binder by thermoregulation 72, equipped with an agitator 73 and level probes 74 and 75.
  • a transfer pump 76 equipped with a prefilter 77 ensures the transfer of the prepared mixes to the buffer tank 83.
  • the various components including the potassium silicate in the liquid state and the dyes, are introduced into the reactor 71 by the dosers 78 and 79, if they are liquid and by the manhole 80, if they are in powder form.
  • the reactor is equipped with a cleaning-rinsing system 81 and a water outlet 82 for emptying.
  • the transfer of the preparation from the reactor 71 to this tank takes place automatically via the pump 76.
  • the tank buffer 83 equipped with level probes 85, 86, 87 and agitator 88 is maintained by thermoregulation 84 at the operating temperature and a recycling circuit ensures by pumping 89 good homogeneity of the product.
  • the metering pump 18 or 18a allows the regulation of the flow rate and of the pressure necessary for spraying the colored silicate.
  • the impregnation into the mass of the vermiculite by the colored binder is preferably carried out by imparting a swirling motion to the particles and by dispersing them within the sprayed binder, for example in the kneader which is also the subject of the patent application. filed today in the name of the applicant.
  • the colored vermiculites from mixers 17 and 17a are mixed in the mixer 18b in the form of a rotating drum with an inclined axis and the inner wall of which is provided with a helical counter-blade, then taken up on the conveyor belt formed of a material. non-stick 19 and screened on the vibrating screen 20 retaining the formation of accidental agglomerates and driving them to a recovery tank 21.
  • the calibrated colored vermiculites are taken up by a conveyor belt 22 equipped with a weighing control system 23, then poured into the hopper 24 of the multilayer spreader distributor which is illustrated in FIG. 3. This second layer therefore comes to be superimposed on the first, simultaneously prepared upstream.
  • the multilayer spreader distributor of FIG. 3 consists of two sets A and B.
  • the set A distributes in one or two separate layers the particles coated on the belt conveyor 25.
  • the flow poured into the hopper 12 is divided in two by two diverging planes 55a and 55b presented by the bottom of the hopper, the common edge 56 of the top of which is situated transversely to the direction of advance of the strip.
  • the two resulting streams are directed to the outlets 41 and 42.
  • the distribution over the width to be formed is ensured by distributing fingers 43a and 43b driven by a movement continuously oscillating on the conveyor 25 provided with two adjustable lateral guides 44 limiting the width.
  • the first bed of particles formed from the overflow 41 passes to the leveling roller 45a exerting a slight pressure of adjustable intensity.
  • the second bed of particles formed from the weir 42 is superimposed on the first: its thickness is adjusted by means of the hatch 46 controlled by the integrated system for adjusting the thickness of the upper layers 47.
  • This second bed of particles passes to the equalizing roller 45b exerting a slight pressure of adjustable intensity.
  • a second set B distributes the colored particles constituting the colored surface layer.
  • This assembly rests on a movable table 48 of the shaping press (FIG. 3) by means of a sliding support 49.
  • the hopper 24 delivers the particles passing over baffled walls, the flow rate being regulated by a hatch 51.
  • distributing arms 52a and 52b animated with an oscillating movement are placed in said outlet baffles.
  • the flow of individual particles then ends up in the weir 53 where their distribution in rain on the moving cake is managed by a distribution reel 54 with Z-shaped blades.
  • the reduction of clods in particles, then the leveling produced by the reel 54 make it possible to adjust the thickness of this layer and, in particular, to reduce this thickness to a minimum.
  • a shaping machine Downstream of the multilayer spreader distributor, a shaping machine is pressed by pressing the cake formed, designated by reference 26 (see FIG. 4).
  • the preformed cake transported by the belt conveyor 25 moves towards the machine 26 to undergo a precompression necessary for the formation of a compact assembly which can be sectioned without exhibiting furring or crumbling detrimental to the good performance.
  • the conveyor slides on an oscillating mobile table 48 driven by a deformable parallelogram composed of connecting rods 67a and 67b and by the kinetic assembly 65 connected by chains and sprockets to a motor 64.
  • This same motor also drives a pulley 66 having an eccentric to which is linked by articulation 63 a crank-rod 62 carrying by means of an articulation an upper press plate 60 driven by an alternating vertical movement, the rhythm of which is synchronous with that of the oscillation of the table 48.
  • the motor 64 also drives the transporter 25.
  • the preforming plate 60 linked to the movable table 48 by an articulation 61 ensures a conformation in constant thickness which can be adjustable.
  • the cake composed of the different particles shaped by the machine 26 is then driven by the belt conveyor 25 so as to pass through the shears 27, the operation of which is controlled by a detector 28 adjustable in length and which proceeds to cut the cake to the desired length.
  • the panel thus debited is taken care of by a weighing conveyor 29 whose indications allow the whole process to be controlled, for example by adjusting the flow rate in the distributors 12 and 24.
  • the panels taken up by the belt conveyor 29 are introduced into the press 31 to be molded. Leaving the press, the panels are then placed in stages in the drying tunnel 33 via the elevator conveyor 32.
  • the drying carried out under determined conditions of time and temperature as a function of the thickness of the panels and of the flow rate, allows the panels reach their final resistance by evaporation of the water from the binder and thus allow its hardening.
  • the panels are trimmed and brushed, then checked.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Laminated Bodies (AREA)
  • Glass Compositions (AREA)
  • Pigments, Carbon Blacks, Or Wood Stains (AREA)
  • Finishing Walls (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Road Signs Or Road Markings (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

Process and plant for the continuous manufacture of coloured panels by continuously depositing on a belt conveyor a bulk-impregnated substance resulting from the kneading of metered quantities of particles such as vermiculite and of an inorganic binder, by forming it into a base layer, by depositing on this layer another layer consisting of particles bulk-impregnated with a coloured binder, in subjecting the set of layers to a precompression and by then cutting them up into panels which, after passing through a press, are subjected to a heat treatment in an oven. <??>Advantages which are inherent in continuous manufacture, to which is added the advantage of a panel coloured by adding to the base layer a bulk-coloured layer which can itself be two-coloured. <IMAGE>

Description

La présente invention se rapporte à un procédé et à une installation pour la fabrication en continu de panneaux colorés de particules ou granulés agglomérés par un liant et en particulier de panneaux constitués de particules de roches exfoliées telles que vermiculites.The present invention relates to a process and to an installation for the continuous manufacture of colored panels of particles or granules agglomerated by a binder and in particular of panels made up of particles of exfoliated rocks such as vermiculites.

En variant les granulométries des matières employées et selon le choix du liant, naturel ou coloré, on obtient une vaste gamme de décors et de couleurs pour des panneaux dont les principales caractéristiques résident dans leur pouvoir d'isolation, leur légèreté, leur rigidité et leurs résistance au feu.By varying the grain sizes of the materials used and according to the choice of binder, natural or colored, we obtain a wide range of decorations and colors for panels whose main characteristics lie in their power of insulation, their lightness, their rigidity and their fire resistance.

Une installation et un dispositif de production en continu de panneaux de béton à plusieurs couches est décrite dans le document DE-A-1 815 973. Le procédé décrit dans ce document est caractérisé en ce qu'en même temps que l'on forme la couche support de béton, on dépose sur cette couche une ou plusieurs couches de béton constituant une surface visible; ces couches sont tassées ensemble. Le dispositif proposé comprend un répartiteur étaleur multicouche, constitué par une bande de transport associée à au moins deux distributeurs de béton; chacun de ces distributeurs est suivi d'un rouleau de compression.An installation and a device for the continuous production of multi-layer concrete panels is described in document DE-A-1 815 973. The process described in this document is characterized in that at the same time as the concrete support layer, one or more layers of concrete are deposited on this layer constituting a visible surface; these layers are packed together. The proposed device comprises a multilayer spreader distributor, constituted by a conveyor belt associated with at least two concrete distributors; each of these distributors is followed by a compression roller.

Dans le document FR-A-2 286 085 est décrite une machine distributrice automatique de matériaux en vrac, sur une route ou un support analogue fixe. Cette machine comprend un châssis supportant une trémie de stockage et un organe de distribution pour le matériau à distribuer; le châssis et animé d'un mouvement de translation relatif par rapport aux organes récepteurs. L'organe de distribution est constitué d'une colonne sensiblement verticale reliée à la sortie de la trémie par un plan incliné. Il est proposé d'associer la trémie à deux colonnes de distribution, chacune coopérant avec un plan incliné différent, ou encore d'utiliser plusieurs trémies pour distribuer en couche des matériaux différents.In document FR-A-2 286 085 is described an automatic machine for distributing bulk materials, on a road or a similar fixed support. This machine comprises a chassis supporting a storage hopper and a dispensing member for the material to be dispensed; the chassis and driven by a relative translational movement relative to the receiving members. The dispensing member consists of a substantially vertical column connected to the outlet of the hopper by an inclined plane. It is proposed to associate the hopper with two distribution columns, each cooperating with a different inclined plane, or even to use several hoppers for distributing different materials in layers.

Dans le document DE-A-934 818, est proposé un dispositif de production en continu de plaques de toit en ciment, dans lequel sont disposés en série sur une bande de transport une trémie avec une racle réglable en hauteur, un dispositif d'arasement, un rouleau de précompression profilé, une presse constituée d'un marteau, assurant un effet de pressage et de frappe, perpendiculairement à la masse et dans le sens de son déplacement, un diffuseur de couleur et enfin un dispositif de lissage.In document DE-A-934 818, there is provided a device for the continuous production of cement roof plates, in which are arranged in series on a conveyor belt a hopper with a doctor blade adjustable in height, a leveling device , a profiled precompression roller, a press consisting of a hammer, ensuring a pressing and striking effect, perpendicular to the mass and in the direction of its movement, a color diffuser and finally a smoothing device.

Les deux premiers documents n'assurent pas une compression suffisante des couches obtenues; ces machines conviennent très bien pour le béton, mais ne permettent pas d'obtenir des panneaux de particules légères, qui doivent être denses et compressées pour présenter une rigidité et une solidité suffisante.The first two documents do not ensure sufficient compression of the layers obtained; these machines are very suitable for concrete, but do not make it possible to obtain panels of light particles, which must be dense and compressed to have sufficient rigidity and solidity.

Le dernier document assure une compression des plaques à l'aide d'une presse située au-dessus de la bande de transport, ce qui conduit à une machine de structure assez haute.The last document provides compression of the plates using a press located above the conveyor belt, which leads to a machine of fairly high structure.

Le problème que l'invention propose de résoudre est d'obtenir une machine du type de celle décrite dans le document DE-A-1 815 973, qui permette d'obtenir des panneaux denses, solides et rigides, avec une bonne compression des panneaux, tout en gardant à la machine de compression une structure assez basse.The problem that the invention proposes to solve is to obtain a machine of the type described in document DE-A-1 815 973, which makes it possible to obtain dense, solid and rigid panels, with good compression of the panels. , while keeping the compression machine a fairly low structure.

Le procédé selon l'invention présente de nombreux avantages par rapport aux procédés connus.The method according to the invention has many advantages over known methods.

En effet, la conduite du procédé en continu permet une parfaite préparation des matériaux en assurant une reproductibilité des caractéristiques de formation, de composition et de qualités identiques de chaque panneau produit. Les moyens de contrôle et de pilotage de l'installation offrant toutes les garanties de dosage de particules et de liants, le fonctionnement en continu permet de minimiser le nombre de préparations à stocker par la mise en oeuvre de petites quantités adaptées à la demande, évitant de ce fait des stockages importants.Indeed, the conduct of the continuous process allows perfect preparation of the materials while ensuring reproducibility of the characteristics of formation, composition and identical qualities of each panel produced. The means of control and piloting of the installation offering all the guarantees of dosing of particles and binders, the continuous operation makes it possible to minimize the number of preparations to be stored by the implementation of small quantities adapted to the request, avoiding therefore significant storage.

L'obtention de la coloration du panneau s'obtient, par l'adjonction à la couche de base imprégnée de liant naturel d'une couche colorée dans la masse grâce à l'emploi du liant coloré lui-même, qui pénètre au cours de l'imprégnation dans la masse de particules traitées et confère au panneau ainsi obtenu une coloration constante et durable.The coloring of the panel is obtained by adding to the base layer impregnated with natural binder with a colored layer in the mass thanks to the use of the colored binder itself, which penetrates during the impregnation in the mass of treated particles and gives the panel thus obtained a constant coloration and durable.

Par ailleurs, le procédé selon l'invention permet la constitution de panneaux en plusieurs couches, d'où la possibilité d'appliquer des granulométries et matériaux différents pour chaque couche, ainsi que de varier les épaisseurs et le nombre de couches.Furthermore, the method according to the invention allows the constitution of panels in several layers, hence the possibility of applying different particle sizes and materials for each layer, as well as of varying the thicknesses and the number of layers.

Grâce à la machine de conformation de l'invention, la structure de la machine est plus basse que celle des machines connues.Thanks to the shaping machine of the invention, the structure of the machine is lower than that of known machines.

La présente invention fournit donc un procédé de fabrication de panneaux colorés de particules ou granulés minéraux agglomérés par un liant, dans lequel on dépose en continu sur une surface de formation mobile une matière résultant du malaxage de quantités dosées desdites particules et d'un liant inorganique à l'état liquide ou visqueux, on l'égalise et la tasse légèrement pour former au moins une couche de base, on dépose en continu sur ladite couche de base au moins une autre couche supérieure, formée par une masse des particules de la même nature, au préalable émiettée, et imprégnée d'un liant coloré, l'ensemble de couches en mouvement de translation sur la surface de formation, après arasement au moins de la couche supérieure, étant soumis à une précompression, puis découpé en panneaux, caractérisé en ce que ladite précompression est réalisée par pressage en continu à l'aide d'un plateau supérieur de préformage animé d'un mouvement vertical alternatif et d'un mouvement horizontal oscillant synchrone, et en ce que lesdits panneaux sont soumis à un moulage dans une presse, puis à un traitement thermique au four.The present invention therefore provides a process for manufacturing colored panels of mineral particles or granules agglomerated by a binder, in which a material resulting from the mixing of metered quantities of said particles and an inorganic binder is continuously deposited on a mobile formation surface. in the liquid or viscous state, it is equalized and slightly cup to form at least one base layer, there is continuously deposited on said base layer at least one other upper layer, formed by a mass of particles of the same nature, previously crumbled, and impregnated with a colored binder, the set of layers in translational movement on the forming surface, after at least leveling the upper layer, being subjected to precompression, then cut into panels, characterized in that said precompression is carried out by continuous pressing using an upper preforming plate animated by a vertical movement al reciprocating and a synchronous horizontal oscillating movement, and in that said panels are subjected to a molding in a press, then to a heat treatment in the oven.

Selon un mode de réalisation du procédé de l'invention, les particules utilisées sont des particules de roches exfoliées, telles que vermiculite, de granulométrie comprise entre 0,3 et 4 mm et que le liant est un silicate alcalin présentant une viscosité de l'ordre de 350 mPa.According to one embodiment of the process of the invention, the particles used are particles of exfoliated rocks, such as vermiculite, with a particle size of between 0.3 and 4 mm and that the binder is an alkali silicate having a viscosity of the around 350 mPa.

Selon un autre mode de réalisation du procédé de l'invention, la coloration de la masse des particules est effectuée en imprimant aux particules un mouvement tourbillonnaire pour les disperser au sein du liant coloré pulvérisé.According to another embodiment of the method of the invention, the coloring of the mass of the particles is carried out by imparting to the particles a vortex movement to disperse them within the sprayed colored binder.

De préférence, la granulométrie des particules servant à la préparation de la couche colorée est différente de celle des particules des autres couches.Preferably, the particle size of the particles used for the preparation of the colored layer is different from that of the particles of the other layers.

Selon une forme d'exécution du procédé de l'invention, la surface de formation mobile est constituée par une bande de transport associée à au moins deux distributeurs de particules imprégnées, dont le premier distributeur de particules non colorées est composé d'une trémie dont le fond présente deux plans divergents dont l'arête commune du sommet est située transversalement par rapport au sens d'avancement de la bande et dont les écartements des parois de la trémie constituent des déversoirs, l'arête inférieure d'un desdits plans situé en amont par rapport à l'arête du sommet constituant un seuil déterminant le niveau d'une première couche en provenance du premier déversoir, tandis qu'une trappe ou réglette réglable en hauteur placée en aval du premier distributeur détermine l'épaisseur d'une deuxième couche en provenance du deuxième déversoirs, un rouleau de compression étant placé en aval de chaque déversoir et dont le second distributeur de particules imprégnées colorées placé en aval du premier est muni de moyens assurant l'émiettement de la masse et l'arasement de la couche déposée.According to one embodiment of the method of the invention, the mobile forming surface is constituted by a strip transport associated with at least two distributors of impregnated particles, of which the first distributor of non-colored particles is composed of a hopper whose bottom has two divergent planes whose common edge of the summit is located transversely to the direction of advance of the strip and whose spacings from the walls of the hopper constitute weirs, the lower edge of one of said planes located upstream relative to the edge of the summit constituting a threshold determining the level of a first layer coming from the first weir, while a height-adjustable hatch or strip placed downstream of the first distributor determines the thickness of a second layer coming from the second weir, a compression roller being placed downstream of each weir and of which the second distributor of colored impregnated particles placed downstream of the first is provided with means ensuring the crumbling of the mass and the leveling ment of the deposited layer.

Selon une autre forme d'exécution du procédé de l'invention, les moyens assurant l'émiettement de la masse et l'arasement de la couche supérieure consistent en des parois de la trémie placées en chicanes et en un moulinet de répartition muni de pales tournantes.According to another embodiment of the method of the invention, the means ensuring the crumbling of the mass and the leveling of the upper layer consist of walls of the hopper placed in baffles and in a reel of distribution provided with blades rotating.

Selon encore une autre forme d'exécution du procédé de l'invention, les niveaux de la réglette du premier distributeur et du déversoir du deuxième distributeur sont asservis à un système intégré de réglage des épaisseurs des couches supérieures.According to yet another embodiment of the process of the invention, the levels of the strip of the first distributor and of the weir of the second distributor are controlled by an integrated system for adjusting the thicknesses of the upper layers.

Selon une autre forme encore d'exécution du procédé de l'invention, le gâteau, composé des couches formées préalablement, est conformé par pressage en continu à l'aide d'un plateau supérieur de préformage réglable par une articulation, entraîné en un mouvement vertical alternatif au moyen d'une manivelle articulée à un excentrique placée sur une poulie, et entraîné en un mouvement horizontal oscillant synchrone.According to yet another embodiment of the method of the invention, the cake, composed of the layers previously formed, is shaped by continuous pressing using an upper preforming plate adjustable by an articulation, driven in a movement vertical alternative by means of a crank articulated to an eccentric placed on a pulley, and driven in a synchronous oscillating horizontal movement.

Selon une autre forme d'exécution du procédé de l'invention, un seul moteur entraîne en rotation au moyen de courroies un ensemble cinématique assurant l'oscillation d'une table mobile et la poulie actionnant la manivelle du plateau de presse.According to another embodiment of the method of the invention, a single motor drives in rotation by means of belts a kinematic assembly ensuring the oscillation of a movable table and the pulley actuating the crank of the press plate.

Selon une autre forme d'exécution encore du procédé, on utilise des moyens de recirculation pour le liant coloré obtenu pour assurer une température constante désirée et une bonne homogénéité du liant coloré.According to yet another embodiment of the method, recirculation means are used for the colored binder obtained to ensure a desired constant temperature and good homogeneity of the colored binder.

L'invention a également pour objet une installation pour la mise en oeuvre du procédé de l'invention, comprenant des unités de préparation des masses imprégnées de liant, des moyens de transfert en continu desdites masses vers un répartiteur étaleur multicouche, ledit répartiteur étant constitué par une bande de transport associée à au moins deux distributeurs de particules imprégnées, un rouleau de compression étant placé en aval d'au moins un desdits distributeurs, caractérisé en ce que le premier distributeur est un distributeur de particules non colorées composé d'une trémie, dont le fond présente deux plans divergents dont l'arête commune du sommet est située transversalement par rapport au sens d'avancement de la bande et dont les écartements des parois de la trémie constituent des déversoirs, en ce que l'arête inférieure d'un desdits plans situé en amont par rapport à l'arête du sommet constitue un seuil déterminant le niveau d'une première couche en provenance du premier déversoir, tandis qu'une trappe ou réglette réglable en hauteur placée en aval du distributeur détermine l'épaisseur d'une deuxième couche en provenance du deuxième déversoir, en ce que le second distributeur est un distributeur de particules imprégnées colorées, placé en aval du premier distributeur, et muni de parois de trémie placées en chicanes assurant l'émiettement de la masse et d'un déversoir à moulinet de répartition muni de pales tournantes assurant l'émiettement de la masse et l'arasement de la couche déposée, et en ce que ladite installation comporte en outre en aval dudit répartiteur étaleur multicouche une machine de conformation par pressage en continu à l'aide d'un plateau supérieur de préformage animé d'un mouvement vertical alternatif et d'un mouvement horizontal oscillant synchrone, une cisaille, pour le découpage en panneaux de la masse provenant de ladite machine de conformation, une presse pour le moulage des panneaux ainsi découpés et un tunnel sécheur, pour le traitement thermique desdits panneaux.The invention also relates to an installation for implementing the method of the invention, comprising units for preparing masses impregnated with binder, means for continuously transferring said masses to a multilayer spreader distributor, said distributor being constituted by a conveyor belt associated with at least two distributors of impregnated particles, a compression roller being placed downstream of at least one of said distributors, characterized in that the first distributor is a distributor of non-colored particles composed of a hopper , the bottom of which has two divergent planes, the common edge of the top of which is situated transversely to the direction of advancement of the strip and the spacings of the walls of the hopper of which constitute weirs, in that the lower edge of one of said planes located upstream relative to the edge of the summit constitutes a threshold determining the level of a first co uche from the first weir, while a height-adjustable hatch or strip placed downstream of the distributor determines the thickness of a second layer coming from the second weir, in that the second distributor is a distributor of colored impregnated particles , placed downstream of the first distributor, and provided with hopper walls placed in baffles ensuring the crumbling of the mass and a distribution reel weir provided with rotating blades ensuring the crumbling of the mass and the leveling of the deposited layer, and in that said installation further comprises downstream of said multilayer spreader distributor a shaping machine by continuous pressing using an upper preforming plate driven by an alternating vertical movement and a horizontal movement oscillating synchronous, a shear, for cutting into panels the mass coming from said shaping machine, a press for molding of panels thus cut and a drying tunnel, for the heat treatment of said panels.

Selon une autre forme d'exécution de ladite installation, les niveaux de la réglette du premier distributeur et du déversoir du deuxième distributeur sont asservis à un système intégré de réglage des épaisseurs des couches supérieures.According to another embodiment of said installation, the levels of the strip of the first distributor and of the weir of the second distributor are controlled by an integrated system for adjusting the thicknesses of the upper layers.

Selon une autre forme d'exécution encore de ladite installation, ladite machine de conformation par pressage en continu assure le pressage en continu du gâteau composé des couches formées préalablement, défilant sur une surface de formation, à l'aide d'un plateau supérieur de préformage animé d'un mouvement vertical alternatif et fixé par une articulation sur une table mobile animée d'un mouvement horizontal oscillant synchrone, ledit plateau supérieur de préformage étant entraîné en un mouvement vertical alternatif au moyen d'une manivelle articulée à un excentrique placée sur une poulie.According to yet another embodiment of said installation, said shaping machine by continuous pressing ensures continuous pressing of the cake composed of the layers previously formed, running on a forming surface, using an upper plate of preforming with an alternating vertical movement and fixed by an articulation on a movable table animated with a synchronous oscillating horizontal movement, said upper preforming plate being driven in an alternating vertical movement by means of a crank articulated to an eccentric placed on a pulley.

Selon un mode de réalisation de ladite installation, un seul moteur entraîne en rotation au moyen de courroies un ensemble cinématique assurant l'oscillation de la table mobile et la poulie actionnant la manivelle du plateau supérieur de préformage.According to one embodiment of said installation, a single motor drives in rotation by means of belts a kinematic assembly ensuring the oscillation of the movable table and the pulley actuating the crank of the upper preforming plate.

Selon encore un mode de réalisation de ladite installation, l'une desdites unités de préparation des masses imprégnées de liant est une sous-unité de préparation de liant coloré qui est constituée d'un réacteur à double enveloppe équipé d'un agitateur, de sondes de niveaux et de pompe de transfert vers une cuve tampon et qui est muni en outre d'ouvertures d'alimentation en quantités dosées de liant, d'eau et de matières colorantes.According to yet another embodiment of said installation, one of said units for preparing masses impregnated with binder is a sub-unit for preparing colored binder which consists of a jacketed reactor equipped with an agitator, probes levels and pump transfer to a buffer tank and which is further provided with feed openings in metered quantities of binder, water and coloring matter.

D'autres particularités et avantages de l'invention apparaîtront à la lumière de la description d'un mode de réalisation présenté à titre d'exemple, illustré par les dessins, dont:

  • la figure 1 représente un schéma de fabrication de panneaux selon l'invention;
  • la figure 2 présente schématiquement la préparation des liants colorés;
  • la figure 3 présente le dispositif de distribution, de répartition et d'égalisation en continu des couches déposées; et
  • la figure 4 présente la machine de conformation par pressage.
Other features and advantages of the invention will become apparent in the light of the description of an embodiment presented by way of example, illustrated by the drawings, including:
  • FIG. 1 represents a diagram for manufacturing panels according to the invention;
  • Figure 2 shows schematically the preparation of colored binders;
  • Figure 3 shows the device for continuous distribution, distribution and equalization of the deposited layers; and
  • Figure 4 shows the pressing machine.

La vermiculite employée a été obtenue par exfoliation par choc thermique, puis dépoussiérée et libérée de toute impureté, de façon à présenter une masse volumique apparente et une granulométrie constantes.The vermiculite used was obtained by exfoliation by thermal shock, then dusted and freed from all impurities, so as to have an apparent density and a constant particle size.

Le liant est un silicate alcalin tel qu'un silicate de potassium sous forme liquide, de densité et viscosité déterminées. Il est maintenu à sa température d'utilisation par cyclage continu et thermorégulation.The binder is an alkaline silicate such as potassium silicate in liquid form, of specific density and viscosity. It is maintained at its operating temperature by continuous cycling and thermoregulation.

Les fines particules de vermiculite sont admises en continu dans le silo 1, équipé de sondes de niveaux, ce silo constituant une réserve tampon suffisante au bon fonctionnement de l'installation et permettant la mise en réserve des trop pleins pouvant provenir d'une différence des débits entre les fours d'exfoliation et la demande de l'installation de fabrication des panneaux.Fine particles of vermiculite are continuously admitted into silo 1, equipped with level probes, this silo constituting a buffer reserve sufficient for the proper functioning of the installation and allowing the overfilling which may come from a difference in the flow rates between exfoliation ovens and demand from the panel manufacturing facility.

Les particules sont reprises à la sortie du silo 1 par un ensemble de transport et de dosage en continu mettant en oeuvre une vanne de limitation de débit 2, un transporteur à bande 3 défilant en continu et un système de pesée 4.The particles are taken up at the outlet of the silo 1 by a continuous transport and metering assembly using a flow limitation valve 2, a conveyor belt 3 continuously scrolling and a weighing system 4.

Dans le malaxeur 6 convergent la vermiculite et le silicate de potassium. L'enrobage des particules de vermiculite s'effectue en imprimant aux particules un mouvement tourbillonnaire et en les dispersant au sein du liant pulvérisé, par exemple dans un malaxeur faisant l'objet d'une demande de brevet également déposée ce jour au nom de la déposante. Le débit et la pression sont assurés par la pompe doseuse 5. En sortie du malaxeur 6, la vermiculite enrobée est reprise en continu par le transporteur à bande 7 pour être criblée sur un tamis vibrant 8 retenant les formations d'agglomérats accidentels et les entraînant vers un bac de récupération 9.In mixer 6 converge vermiculite and potassium silicate. The vermiculite particles are coated by imparting a swirling motion to the particles and by dispersing them within the sprayed binder, for example in a mixer which is the subject of a patent application also filed today in the name of the depositor. The flow rate and the pressure are provided by the metering pump 5. At the outlet of the mixer 6, the coated vermiculite is continuously taken up by the belt conveyor 7 to be screened on a vibrating screen 8 retaining the formation of accidental agglomerates and driving them to a recycling bin 9.

La vermiculite enrobée est reprise en continu par un transporteur à bande en matière anti-adhésive 10 avec contrôle de pesée 11.The coated vermiculite is taken up continuously by a conveyor belt made of non-stick material 10 with weighing control 11.

Le contrôle de pesée a pour but le bilan des matières et le réglage du débit de vermiculite en 2 et du débit de silicate par la pompe doseuse 5.The purpose of the weighing control is to balance the materials and adjust the vermiculite flow in 2 and the silicate flow by the metering pump 5.

Du transporteur à bande 10 la vermiculite enrobée se déverse dans la trémie double 12 du répartiteur étaleur multicouche pour constituer la couche inférieure de panneau ou la couche de base.From the belt conveyor 10 the coated vermiculite pours into the double hopper 12 of the multilayer spreader distributor to form the lower panel layer or the base layer.

Quant à la préparation de la couche de vermiculite colorée, dont l'apport s'effectue au moyen du dispositif 24, celle-ci s'opère à partir du silo 13.As for the preparation of the colored vermiculite layer, which is supplied by means of the device 24, this takes place from the silo 13.

L'installation de préparation de la couche colorée présentée à la figure 1 est composée des deux lignes de préparation permettant l'obtention des deux masses de coloration différente destinées à être mélangées pour l'obtention d'une couche bicolore.The installation for preparing the colored layer presented in FIG. 1 is composed of the two preparation lines allowing the production of the two masses of different coloring intended to be mixed in order to obtain a two-color layer.

Reprise à la sortie du silo 13 par des transporteurs à bande 15, 15a respectivement, la vermiculite est dosée par une vanne de limitation de débit 14, et est contrôlée par un système de pesée 16. Dans les malaxeurs 17, 17a convergent la vermiculite et le silicate de potassium préalablement coloré, dont la préparation suit. (figure 2).Resumption at the outlet of the silo 13 by belt conveyors 15, 15a respectively, the vermiculite is metered by a flow limiting valve 14, and is controlled by a weighing system 16. In the mixers 17, 17a converge the vermiculite and potassium silicate previously colored, the preparation of which follows. (figure 2).

La préparation du liant coloré s'effectue de préférence dans un réacteur 71 à enveloppe chauffante assurant une température d'utilisation de liant constante par thermorégulation 72, équipé d'un agitateur 73 et de sondes de niveaux 74 et 75. Une pompe de transfert 76 équipée d'un préfiltre 77 assure le transfert des mélanges préparés vers la cuve tampon 83.The preparation of the colored binder is preferably carried out in a reactor 71 with a heating jacket ensuring a constant temperature of use of binder by thermoregulation 72, equipped with an agitator 73 and level probes 74 and 75. A transfer pump 76 equipped with a prefilter 77 ensures the transfer of the prepared mixes to the buffer tank 83.

Les différentes composants, y compris le silicate de potassium à l'état liquide et les colorants, sont introduits dans le réacteur 71 par les doseurs 78 et 79, s'ils sont liquides et par le trou d'homme 80, s'ils sont sous forme de poudre.The various components, including the potassium silicate in the liquid state and the dyes, are introduced into the reactor 71 by the dosers 78 and 79, if they are liquid and by the manhole 80, if they are in powder form.

Le réacteur est équipé d'un système de nettoyage - rinçage 81 et d'une évacuation des eaux 82 pour vidange.The reactor is equipped with a cleaning-rinsing system 81 and a water outlet 82 for emptying.

Si le niveau de la cuve tampon l'autorise, le transfert de la préparation du réacteur 71 à cette cuve s'effectue automatiquement par l'intermédiaire de la pompe 76. La cuve tampon 83 équipée de sondes de niveaux 85, 86, 87 et d'agitateur 88 est maintenue par thermorégulation 84 à la température d'utilisation et un circuit de recyclage assure par pompage 89 une bonne homogénéité du produit.If the level of the buffer tank allows it, the transfer of the preparation from the reactor 71 to this tank takes place automatically via the pump 76. The tank buffer 83 equipped with level probes 85, 86, 87 and agitator 88 is maintained by thermoregulation 84 at the operating temperature and a recycling circuit ensures by pumping 89 good homogeneity of the product.

Par piquage sur ledit circuit de recyclage, la pompe doseuse 18 ou 18a permet la régulation du débit et de la pression nécessaire à la pulvérisation du silicate coloré.By stitching on said recycling circuit, the metering pump 18 or 18a allows the regulation of the flow rate and of the pressure necessary for spraying the colored silicate.

L'imprégnation dans la masse de la vermiculite par le liant coloré s'effectue de préférence en imprimant aux particules un mouvement tourbillonnaire et en les dispersant au sein du liant pulvérisé, par exemple dans le malaxeur faisant l'objet de la demande de brevet également déposée ce jour au nom de la déposante.The impregnation into the mass of the vermiculite by the colored binder is preferably carried out by imparting a swirling motion to the particles and by dispersing them within the sprayed binder, for example in the kneader which is also the subject of the patent application. filed today in the name of the applicant.

Les vermiculites colorées provenant de malaxeurs 17 et 17a sont mélangées dans le mélangeur 18b en forme de tambour tournant à axe incliné et dont la paroi intérieure est pourvue d'une contre-pale hélicoïdale, puis reprises sur le transporteur à bande formée d'un matériau anti-adhérent 19 et criblées sur le tamis vibrant 20 retenant les formations d'agglomérats accidentels et les entraînant vers un bac de récupération 21.The colored vermiculites from mixers 17 and 17a are mixed in the mixer 18b in the form of a rotating drum with an inclined axis and the inner wall of which is provided with a helical counter-blade, then taken up on the conveyor belt formed of a material. non-stick 19 and screened on the vibrating screen 20 retaining the formation of accidental agglomerates and driving them to a recovery tank 21.

Les vermiculites colorées calibrées sont reprises par un transporteur à bande 22 équipé d'un système de contrôle de pesée 23, puis déversées dans la trémie 24 du répartiteur étaleur multicouche qui est illustré sur la figure 3. Cette deuxième couche vient donc se superposer à la première, simultanément préparée en amont.The calibrated colored vermiculites are taken up by a conveyor belt 22 equipped with a weighing control system 23, then poured into the hopper 24 of the multilayer spreader distributor which is illustrated in FIG. 3. This second layer therefore comes to be superimposed on the first, simultaneously prepared upstream.

Le répartiteur étaleur multicouche de la figure 3 est constitué de deux ensembles A et B. L'ensemble A distribue en une ou deux couches séparées les particules enrobées sur le transporteur à bande 25. Le flux déversé dans la trémie 12 est divisé en deux par deux plans 55a et 55b divergeants que présente le fond de la trémie, dont l'arête commune 56 du sommet est située transversalement par rapport au sens d'avancement de la bande. Les deux flux résultants sont dirigés vers les sorties-déversoirs 41 et 42.The multilayer spreader distributor of FIG. 3 consists of two sets A and B. The set A distributes in one or two separate layers the particles coated on the belt conveyor 25. The flow poured into the hopper 12 is divided in two by two diverging planes 55a and 55b presented by the bottom of the hopper, the common edge 56 of the top of which is situated transversely to the direction of advance of the strip. The two resulting streams are directed to the outlets 41 and 42.

La répartition sur la largeur à constituer est assurée par des doigts répartiteurs 43a et 43b animés d'un mouvement oscillant continu sur le transporteur 25 muni de deux guides latéraux réglables 44 limitant la largeur.The distribution over the width to be formed is ensured by distributing fingers 43a and 43b driven by a movement continuously oscillating on the conveyor 25 provided with two adjustable lateral guides 44 limiting the width.

Le premier lit de particules formé à partir du déversoir 41 passe au rouleau égalisateur 45a exerçant une légère pression d'intensité réglable.The first bed of particles formed from the overflow 41 passes to the leveling roller 45a exerting a slight pressure of adjustable intensity.

Le deuxième lit de particules formé à partir du déversoir 42 se superpose au premier: son épaisseur est réglée par l'intermédiaire de la trappe 46 asservie au système intégré de réglage de l'épaisseur des couches supérieures 47.
Ce deuxième lit de particules passe au rouleau égalisateur 45b exerçant une légère pression d'intensité réglable.The second bed of particles formed from the weir 42 is superimposed on the first: its thickness is adjusted by means of the hatch 46 controlled by the integrated system for adjusting the thickness of the upper layers 47.
This second bed of particles passes to the equalizing roller 45b exerting a slight pressure of adjustable intensity.

A ce stade des panneaux peuvent être fabriqués à partir de ces deux couches: ils sont alors de couleur naturelle.At this stage panels can be made from these two layers: they are then natural in color.

Un deuxième ensemble B distribue les particules colorées constituant la couche superficielle colorée. Cet ensemble repose sur une table mobile 48 de la presse de conformation (figure 3) par l'intermédiaire d'un support coulissant 49.A second set B distributes the colored particles constituting the colored surface layer. This assembly rests on a movable table 48 of the shaping press (FIG. 3) by means of a sliding support 49.

La trémie 24 délivre les particules passant sur des parois en chicane, le débit étant réglé par une trappe 51. Pour produire l'émiettement et briser les mottes de particules, des bras répartiteurs 52a et 52b animés d'un mouvement oscillant sont placés dans lesdites chicanes de sortie. Le flux de particules individuelles aboutit alors dans le déversoir 53 où leur distribution en pluie sur le gâteau défilant est géré par un moulinet de répartition 54 à pales en forme de Z. La réduction de mottes en particules, puis l'arasement produit par le moulinet 54 permettent de régler l'épaisseur de cette couche et, notamment, de réduire à un minimum cette épaisseur.The hopper 24 delivers the particles passing over baffled walls, the flow rate being regulated by a hatch 51. To produce the crumbling and break up the clods of particles, distributing arms 52a and 52b animated with an oscillating movement are placed in said outlet baffles. The flow of individual particles then ends up in the weir 53 where their distribution in rain on the moving cake is managed by a distribution reel 54 with Z-shaped blades. The reduction of clods in particles, then the leveling produced by the reel 54 make it possible to adjust the thickness of this layer and, in particular, to reduce this thickness to a minimum.

En aval du répartiteur étaleur multicouche est placée une machine de conformation par pressage du gâteau formé, désignée par repère 26 (voir figure 4).Downstream of the multilayer spreader distributor, a shaping machine is pressed by pressing the cake formed, designated by reference 26 (see FIG. 4).

Le gâteau préformé transporté par le transporteur à bande 25 se déplace vers la machine 26 pour y subir une précompression nécessaire pour la formation d'un ensemble compact pouvant être sectionné sans présenter de félure ou émiettage préjudiciable à la bonne tenue.The preformed cake transported by the belt conveyor 25 moves towards the machine 26 to undergo a precompression necessary for the formation of a compact assembly which can be sectioned without exhibiting furring or crumbling detrimental to the good performance.

Le transporteur glisse sur une table mobile oscillante 48 entraînée par un parallélogramme déformable composé de bielles 67a et 67b et par l'ensemble cinétique 65 raccordé par chaînes et pignons à un moteur 64. Ce même moteur entraîne également une poulie 66 présentant un excentrique auquel est liée par articulation 63 une bielle-manivelle 62 portant par l'intermédiaire d'une articulation un plateau de presse supérieur 60 animé d'un mouvement vertical alternatif, dont le rythme est synchrone avec celui de l'oscillation de la table 48. Le moteur 64 entraîne également le transporteur 25.The conveyor slides on an oscillating mobile table 48 driven by a deformable parallelogram composed of connecting rods 67a and 67b and by the kinetic assembly 65 connected by chains and sprockets to a motor 64. This same motor also drives a pulley 66 having an eccentric to which is linked by articulation 63 a crank-rod 62 carrying by means of an articulation an upper press plate 60 driven by an alternating vertical movement, the rhythm of which is synchronous with that of the oscillation of the table 48. The motor 64 also drives the transporter 25.

Le plateau de préformage 60 lié à la table mobile 48 par une articulation 61 assure une conformation en épaisseur constante qui peut être réglable.The preforming plate 60 linked to the movable table 48 by an articulation 61 ensures a conformation in constant thickness which can be adjustable.

Le gâteau composé des différentes particules conformé par la machine 26 est alors entraîné par le transporteur à bande 25 de façon à passer au travers de la cisaille 27, dont le fonctionnement est piloté par un détecteur 28 réglable en longueur et qui procède au sectionnement du gâteau à la longueur voulue. Le panneau ainsi débité est pris en charge par un convoyeur 29 à pesée 30 dont les indications permettent de piloter l'ensemble du procédé, par exemple en réglant le débit dans les distributeurs 12 et 24. Les panneaux repris par le transporteur à bande 29 sont introduits dans la presse 31 pour être moulés. Sortis de la presse les panneaux sont ensuite enfournés par étage dans le tunnel sécheur 33 par l'intermédiaire du transporteur élévateur 32. Le séchage effectué dans des conditions déterminées de temps et de température en fonction de l'épaisseur des panneaux et du débit, permet aux panneaux d'atteindre leur résistance finale par évaporation de l'eau du liant et permettre ainsi son durcissement.The cake composed of the different particles shaped by the machine 26 is then driven by the belt conveyor 25 so as to pass through the shears 27, the operation of which is controlled by a detector 28 adjustable in length and which proceeds to cut the cake to the desired length. The panel thus debited is taken care of by a weighing conveyor 29 whose indications allow the whole process to be controlled, for example by adjusting the flow rate in the distributors 12 and 24. The panels taken up by the belt conveyor 29 are introduced into the press 31 to be molded. Leaving the press, the panels are then placed in stages in the drying tunnel 33 via the elevator conveyor 32. The drying carried out under determined conditions of time and temperature as a function of the thickness of the panels and of the flow rate, allows the panels reach their final resistance by evaporation of the water from the binder and thus allow its hardening.

A la sortie du tunnel, les panneaux sont ébarbés et brossés, puis contrôlés.At the exit of the tunnel, the panels are trimmed and brushed, then checked.

Claims (15)

  1. A process for producing colored panels of mineral particulate or granular exfoliated rock-based material agglomerated by a binder, in which a material resulting from the blending of measured amounts of said particulate matter and an inorganic binder in the liquid or viscous state is continuously deposited onto a movable forming and shaping surface (25) and is then rendered even and slightly compacted in order to form at least one base layer, and at least one further upper layer formed by a mass of particles of the same nature as the first and previously divided into small pieces and which has been thoroughly impregnated with a colored binder is continuously deposited onto said base layer, the combination of said layers moving along said forming and shaping surface (25) and after flattening off of at least the upper layer, undergoing pre-compression and then being cut into panels, characterized in that said precompression is carried out by continuous pressing with the aid of an upper pre-shaping compression plate (60) driver in an alternating vertical motion and a synchronous oscillating horizontal motion, said plate (60) being above the other elements of the shaping machine, and in that said panels are subjected to molding in a press (31) and then to thermal treatment in a kiln (33).
  2. Process according to claim 1, characterized in that the particulate matter employed consists of particles of vermiculite, of a particle size comprised between 0.3 and 4 mm, and the binder is an alkaline silicate having a viscosity of the order of 350 mPa.
  3. Process according to claim 1 or 2, characterized in that the said thorough impregnation of the particulate matter with a colored binder is achieved by imparting a swirling movement thereto in order to intimately disperse said matter within said colored binder provided in spray form.
  4. Process according to any one of claims 1 to 3, characterized in that the particle size of the particulate matter employed for preparing said colored layer is different from the particle size of the other layers.
  5. Process according to any one of claims 1 to 4, characterized in that said movable forming and shaping surface is constituted by a conveyer-belt (25) associated with at least two distributors for impregnated particles (A, B) the first (A) of said distributors feeding non-colored particles and being made up by a hopper (12) with a base having two diverging surfaces (55a, 55b) originating from a common line (56) which is located transversally with respect to the direction of advance of said conveyer-belt with the spacings between the walls of said hopper and said diverging surfaces respectively constituting first and second pouring means (41, 42), the lower edge of one of said surfaces which is located in advance, with respect to said direction of travel, of said common line constituting a limiting means determining the height of a first layer being provided from the first pouring means of said hopper while a variable-height sliding plate means (46) located after, in said direction of travel, said first distributor determines the thickness of a second layer being provided by the second pouring means (42) of said hopper, a compression roller (45a, 45b) being located after each of said first and second pouring means, the second of said distributors feeding colored particles and being located, in the direction of travel, after said first distributor (A) and being provided with means for breaking up said impregnated colored particulate matter into small pieces and for flattening the layer deposited.
  6. Process according to any one of claims 1 to 5, characterized in that said means providing for the breaking up of said particulate matter into small pieces and for flattening the layer deposited comprise means obliging said impregrated particulate matter to follow a tortuous path within said second distributor and flat-ended vaned (54) rotating means.
  7. Process according to any one of claims 1 to 5, characterized in that the levels of said variable-height sliding plate means (46) of the first distributor (A) and of the point of discharge (53) from said second distributor (B) are controlled by an integrated system (47) for regulating the thicknesses of the upper layers.
  8. Process according to any one of claims 1 to 5, characterized in that a mat composed of the previously formed layers applied by said first and second distributors is subsequently shaped by continuous pressing with the aid of a pre-shaping compression plate (60) the position of which is set by a pivot point (61) at one end thereof and to the other end of which which is driver in an alternating vertical motion by means of a crankshaft (62) pivoting on an eccentric (63) located on a pulley (66), and is driven in a synchronous oscillating horizontal movement.
  9. Process according to claim 8, characterized in that one single motor (64) rotatably drives, by means of a continuous drive means a motion converting assembly (65) providing said alternating movement of a movable table (48), and said pulley (66) operating the crankshaft of said pressure plate.
  10. Process according to any one of claims 1 to 9, characterized in that means are provided for recirculating the colored binder obtained in order to ensure maintenance of a desired constant temperature thereof and good homogeneity of said colored binder.
  11. Installation for carrying out the process according to any one of claims 1 to 9, comprising units for preparing bulk binder-impregnated materials and means for continuously transferring said bulk materials onto a multi-layer distributing and spreading device made up by a conveyer-belt (25) associated with at least two distributors (A, B) for said binder-impregnated bulk matter characterized in that the first (A) of said distributors is for non-colored bulk matter and being made up by a hopper (12) the base of which comprises two diverging surfaces (55a, 55b) the common edge (56) of which is located transversally with respect to the direction of advance of said conveyer-belt with the spacing between the walls of of said hopper constituting pouring means (41, 42), in that the lower edge of one of said surfaces which is located in advance, with respect to said direction of travel, of said common edge constituting a limiting means determining the height of a first layer being provided from said hopper while a variable-height shutter or sliding plate (46) located after, in said direction of travel, said distributor determines the thickness of a second layer provided by a second pouring means (42), and in that the second distributor (B) is for colored impregnated particles located, in the direction of travel after said first distributor (A), the walls of said hopper forming a tortuous path and a spinning distribution device provided with rotating vanes (54) being provided for breaking up said particulate matter into small pieces and for flattening the layer deposited, said means providing for the breaking up of said particulate matter into small pieces and for flattening the upper layer consist of the constitution by .
  12. Installation according to claim 11, characterized in that the levels of said sliding plate (46) of the first distributor (A) and of the pouring means (53) of said second distributor (B) are controlled by an integrated system (47) for regulating the thicknesses of the upper layers.
  13. Installation according to claim 11 or 12, characterized in that said continuous press shaping machine (26) ensures continuous pressing of a cake composed of previously-formed layers passing along a shaping surface (25) with the aid of an upper pre-shaping pressure plate (60) driven with an alternating vertical motion and fixed at a pivot point (61) on a movable table (48) driven with a synchronized horizontal oscillating movement said by means of a crankshaft (62) pivoting on an eccentric pivot, said upper pre-shaping pressure plate (60) being driver with an alternating vertical motion by means of a crankshaft (62) pivoting on an eccentric (63) located on a pulley (66).
  14. Installation according to any one of claims 11 to 13 characterized in that one single motor (64) drives, by means of continuous belt means, a motion converting assembly (65) providing the oscillation of said movable table (48), and said pulley (66) for actuating the crankshaft (62) of said upper pre-shaping pressure plate (60).
  15. Installation according to any one of claims 11 to 14, characterized in that one of said units for preparing colored binder-impregnated masses is a sub-unit for preparing colored binder, said sub-unit comprising a double-walled reaction vessel (71) fitted with agitating means (73), level sensors (74, 75) and with pump means (76) for transfer of said colored binder to a buffer supply tank (83) and which is further provided with openings for the supply of measured amounts (78, 79) of binder, of water and of coloring material.
EP90403107A 1989-11-20 1990-11-02 Process and apparatus for making coloured decorative panels from exfoliated rocks particles Expired - Lifetime EP0429330B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR8915171 1989-11-20
FR8915171A FR2654678B1 (en) 1989-11-20 1989-11-20 PROCESS AND INSTALLATION FOR THE MANUFACTURE OF COLORED DECORATIVE PANELS BASED ON EXFOLIATED ROCK PARTICLES.

Publications (2)

Publication Number Publication Date
EP0429330A1 EP0429330A1 (en) 1991-05-29
EP0429330B1 true EP0429330B1 (en) 1995-01-11

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP90403107A Expired - Lifetime EP0429330B1 (en) 1989-11-20 1990-11-02 Process and apparatus for making coloured decorative panels from exfoliated rocks particles

Country Status (11)

Country Link
US (1) US5145627A (en)
EP (1) EP0429330B1 (en)
JP (1) JPH03231000A (en)
AT (1) ATE116897T1 (en)
AU (1) AU636682B2 (en)
BR (1) BR9005957A (en)
DE (1) DE69015981T2 (en)
DK (1) DK0429330T3 (en)
ES (1) ES2022088T3 (en)
FR (1) FR2654678B1 (en)
GR (1) GR910300093T1 (en)

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IT1287505B1 (en) * 1996-11-22 1998-08-06 Algeri Maris Continuous pressing method and plant for production of tiles - involves controlled discharge of contained layer of powder on conveyor belt that advances through pre-pressing rollers to mould and pressing punch
US7595092B2 (en) * 2006-03-01 2009-09-29 Pyrotite Coating Of Canada, Inc. System and method for coating a fire-resistant material on a substrate
CN101745982B (en) * 2008-12-10 2012-07-04 上海斯米克建筑陶瓷股份有限公司 Vitrified tile weave fabric process
CN101954668B (en) * 2009-07-16 2012-05-16 上海斯米克建筑陶瓷股份有限公司 Process for partitioning and three-dimensional material distribution of ceramic tiles
ES2645974T3 (en) * 2011-04-22 2017-12-11 Vecor Ip Holdings Limited Apparatus, system and methods for forming pressed articles and pressed articles formed by them
AT511804B1 (en) * 2011-11-17 2013-03-15 Berndorf Band Gmbh DEVICE FOR PRODUCING A PLATE OF PLASTIC MATERIAL
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Also Published As

Publication number Publication date
FR2654678A1 (en) 1991-05-24
JPH03231000A (en) 1991-10-14
FR2654678B1 (en) 1994-04-01
AU636682B2 (en) 1993-05-06
DE69015981D1 (en) 1995-02-23
GR910300093T1 (en) 1991-12-10
ES2022088T3 (en) 1995-04-01
ES2022088A4 (en) 1991-12-01
AU6656890A (en) 1991-05-23
EP0429330A1 (en) 1991-05-29
ATE116897T1 (en) 1995-01-15
DK0429330T3 (en) 1995-05-01
DE69015981T2 (en) 1995-08-31
US5145627A (en) 1992-09-08
BR9005957A (en) 1991-09-24

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