IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0466325
(2002-01-17)
|
우선권정보 |
EP-0830064 (2001-01-31) |
국제출원번호 |
PCT//EP02/00424
(2003-07-30)
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§371/§102 date |
20030730
(20030730)
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국제공개번호 |
WO02//060836
(2002-08-08)
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발명자
/ 주소 |
|
출원인 / 주소 |
|
대리인 / 주소 |
Oblon, Spivak, McClelland, Maier &
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인용정보 |
피인용 횟수 :
1 인용 특허 :
6 |
초록
▼
A process id disclosed for structurally repairing and aesthetically filling, and mutually coupling slabs (1) and layers (2?4) into a block (5), comprising the steps of: heating, drying and impregnating the slabs (1) with resin; penetrating the resin through atmospheric pressure; inserting positive p
A process id disclosed for structurally repairing and aesthetically filling, and mutually coupling slabs (1) and layers (2?4) into a block (5), comprising the steps of: heating, drying and impregnating the slabs (1) with resin; penetrating the resin through atmospheric pressure; inserting positive pressures; applying a liquid- or gas-tight sealing coating (6, 7, 8) around the block (5) to allow resin to flow around and inside the block (5), containing hydrostatic resin pressures and checking resin consumptions through a formwork; directly supporting through the block (5) the thrusts generated by pressure differentials; when preparing the block (5), assembling the stone slabs (1) independently from mutual thickness and distance between centers with other stone slabs (1).
대표청구항
▼
1. Process for structurally repairing and aesthetically filling a plurality of slabs made of stone material and, for composites with a backing, providing the plurality of slabs with reinforcing nets or sheets adapted to further increase a tensile and flexural strength thereof, or for coupling said s
1. Process for structurally repairing and aesthetically filling a plurality of slabs made of stone material and, for composites with a backing, providing the plurality of slabs with reinforcing nets or sheets adapted to further increase a tensile and flexural strength thereof, or for coupling said slabs to other slabs of stone material of a same type or a different type, or to slabs made of another material, all said slabs or sheets being dry assembled into a block, interposing layers of plastic separating sheets, said process comprising:heating the stone slabs to be able to dry the stone slabs afterwards and completely under vacuum;inserting said block composed of slabs, nets or sheets in an autoclave adapted to create a vacuum state to dry the slabs, nets or sheets at their core, and afterwards inserting, into a formwork in which the block is contained, resins at liquid state, in a necessary amount for completely impregnating the slabs, nets or sheets, said resins being inserted by pouring on a free upper surface of the block or inserted from a base of the block, a lower part and a perimeter of the block being contained into at least one of a liquid-tight and a gas-tight housing;making said resin penetrate between the layers composing the block and into fractures and flaws of the stone slabs by atmospheric pressure, said atmospheric pressure operating as a piston on the fluid resin accumulated into a space formed above an upper face of the multi-layered block, the resin being thereby injected between the layers and into the flaws and fractures of the slabs;inserting positive pressure into the autoclave;applying a coating around said block, said coating being wrapped around said block under and along a vertical perimeter thereof, said coating being composed of liquid-tight and gas-tight component elements, one of said component elements being higher than the block and wrapped around said block having, its extreme edges mutually connected with a welding or other liquid-impermeable or gas-impermeable connection, said coating being further composed of a liquid-permeable spacer element to space the coating from the block, said coating being formed as a liquid-impermeable and gas-impermeable housing and to allow the resin to flow around and inside the block, elements composing said coating being mutually connected, to form an envelope, by an impermeable structural junction between the liquid-tight and gas-tight component elements;containing hydrostatic pressures of the resin operating from inside to outside the block and controlling resin consumption through a formwork that gets a shape of the block contained therein, components of said formwork that are outside said coating not coming in contact with the impregnation resins, said coating being kept in position by panels and brackets that keep the panels against the block, said brackets being secured by a closing mechanism to a platform adapted to support and transport the block;directly supporting through said blocks generated by pressure differentials occurring during rebalancing steps to the atmospheric pressure of a space inside the autoclave, or when inserting overpressures inside the autoclave;when preparing said block, assembling said stone slabs into the block independently from their mutual thickness and distance between centers with other stone slabs placed at other levels of a composite block, said stone slabs being assembled together with other slabs made of different materials, every group of components of a composite slab being aimed to remain mutually strictly joined through separation by plastic separating sheets from every other equal or different group.2. Process according to claim 1, further comprising preliminary washing said stone slabs before heating said stone slabs.3. Process according to claim 1, wherein said stone slabs are at a sawing plane or are calibrated after sawing and are free from previously-applied nets, mats, or other reinforcements.4. Process according to claim 1, wherein said panels form one continuous panel.5. Process according to claim 1, wherein said panels are a plurality of mutually joined panels.6. Process according to claim 2, wherein said preliminary washing is performed with a jet of water with a pressure higher than 100 atmospheres and said heating occurs at a temperature of 50?60° C.7. Process according to claim 1, wherein said spacer element is shaped as plastic sheets that cannot be glued by the resin and are equipped with positive projections oriented towards the block.8. Process according to claim 1, wherein said spacer element is composed of a woven or non-woven fabric that is permeable to resin flow.9. Process according to claim 1, further comprising, in succession:if necessary, cleaning and freeing from sawing powder residuals, washing with pressurized water, both faces of the slabs made of stone material, and heating said slabs at 50?60° C.;placing a structural panel on a plane structure composed of a general bearing structure, with a bearing plane also formed by a plane part of at least two brackets housed inside said structure, said panel being placed along a starting assembling alignment line of the layers forming a block, said alignment line being backward placed with respect to the following positioning of said layers;longitudinally placing on said panel a liquid-impermeable and gas-impermeable sheet, said sheet being placed at a same longitudinal alignment of the layers composing the block and being placed with an edge projecting from a following transverse head alignment of said layers, said edge being used to join said sheet at its opposite end, a length of said sheet being left a bit longer than what is provided for closing again inside said sheet, by wrapping said sheet, a whole perimeter of the block after that it has been assembled, said sheet being by at least 10 centimeters wider than said layers to be able to be extended from an opposite part to the longitudinal assembling alignment line;placing above the sheet a further sheet that is permeable to a liquid substance, said further sheet being cut at a length that is equal or slightly less than a length of the slabs and at a width that is equal or slightly greater than a width of the layers of different materials, said further sheet being placed along the assembling alignment line of said layers and of the sheet and projecting from an opposite part for a width exceeding the width of said layers;assembling in succession, said layers composed of stone slabs, reinforcement sheets or nets, the plastic separating sheet that cannot be glued and slabs or sheets made of other materials, said layers being all prepared in same dimensions in width and length and longitudinally and transversally aligned in a same way;when the assembling of block has been completed with all programmed materials, placing on the upper face of said block and on blockheads the permeable sheets that complete the perimeter coating, said sheets being placed aligned like the different layers, but being prepared to be slightly projecting from an opposite part to the longitudinal starting alignment and, on the heads, that are equal or slightly shorter than a sum of thicknesses of the assembled layers, and prepared to be slightly projecting from the opposite part to the starting longitudinal alignment, said sheets configured to be replaced by a single sheet covering the upper face and the two heads of the block, said single sheet being prepared to be slightly projecting from the opposite part to the longitudinal starting alignment of the layers;wrapping an impermeable sheet around a perimeter of the block and joining with a liquid-tight and gas-tight joint the two ends of said sheet;placing the second longitudinal structural panel on the upper face of the block and compacting the layers of materials below, operating in areas that do not affect a following positioning of brackets;placing and securing on a process platform a liquid-tight and gas-impermeable sheet, whose length is greater than the length of the layers of the different materials and whose width is similarly greater than the width of the different overlapped layers, to allow performing a welding between the vertical sheet and the horizontal sheet, and afterwards abutting onto said sheet a permeable sheet having sizes that are slightly reduced on a provided length and width of a thickness of the block after having compacted a pack of layers of different materials being overlapped as to form the block, and placing said sheet to be centered with respect to the wall of the block;loading on a plane the process platform on an overturning trolley formed by two planes that are mutually arranged at 90°, said overturning trolley being equipped with a rotation pin that allows the planes to assume one or another position, accurately positioning said process platform on the plane of the overturning trolley prearranged to receive said process platform, and then stiffly securing said process platform to said plane by a securing mechanism;rotating by 90° the trolley planes, if the process platform has been assembled horizontally on said trolley or placing and directly vertically securing said platform and then approaching the other plane composed of two forks to a general bearing structure inserting said forks for all their length into a housing provided therefore in said structure;securing the panel by through-holes obtained in the process platform, by connecting with screws said platform to threaded holes prearranged on a base of the brackets housed in the general bearing structure;afterwards securing the longitudinal panel arranged above the block to the platform with brackets, equipped with a slot arranged in a bearing foot at 90°, with screws passing into blind threaded holes obtained into the platform and that can be reached through said slot, said blind threaded holes being arranged on staggered rows and allowing to secure the brackets in varying positions and measures according to varying thickness of said block;similarly securing the structural head panels to both heads of the block, a type of head panel being chosen to cover a maximum surface of the two heads, and placing the structural panels to then secure them by the brackets, using the suitable threaded holes and rows of holes in the process platform to lock with screws and said structural panels against the block, if it was chosen to close the heads in this process step;rotating by 90° the block completed with its containment systems so that the layers of materials are vertically arranged;if the heads have still not been closed, placing and securing the head panels;connecting with a liquid-tight and gas-tight joint the impermeable sheet wrapping the perimeter and the base impermeable sheet, said connecting step being made possible by the fact that the longitudinal structural panels and the head structural panels are lifted with respect to the bearing plane of the process platform and by the fact that said panels have a thickness of some centimeters and leave a distance that is equal to their thickness between a rear plane part of the brackets and the block, allowing the passage of a drilled hole that dispenses an adhesive for the structural connection;if necessary, to contain hydrostatic pressures, perimetrically support at the base of the block and on its four sides, the impermeable sheet, with stiff containment beams anchored to the process platform or to the brackets, and placed between said brackets and the perimeter of block until a space between the welding and a lower edge of the panels is covered;lifting and laterally displacing the process platform in a way deemed most adequate to free the brackets from constraint of their transverse housing into the general bearing structure, thereby freeing the process platform and allowing to take the process platform back by a 90° rotation of the forks in the trolley to its plane position ready for a following cycle, and allowing said forks to be disengaged through a linear displacement of said trolley;transporting the process platform and the block arranged over the process platform, completed with all its containment structures, into the autoclave and levelling with an air bubble an upper plane of the block;closing access to the autoclave and scavenging air contained therein until a vacuum level is obtained that is as close as possible to zero, but not greater than 5 residual torr;inserting into an autoclave the hardenable resin at liquid state with a pump or exploiting a depression inside the autoclave, and letting the resin drop on the upper face of the block or inserting the resin from below into said block with a pump, until a resin tank is formed with a computed amount that is enough for the block to be impregnated, contained by the perimetrical impermeable sheet that the structural bearing panels support, such resin configured to be freed by air in solution or emulsion before inserting the resin into the autoclave or, if poured from above, configured to temporarily stay into a vessel placed above the block into the autoclave and left there for a necessary time to free the resin from the air, to then control from an outside opening of the vessel or its slanting to make the resin fall down on the surface of the block, with the resin that starts seeping under, along the walls and between the layers of the block;afterwards putting the autoclave in communication with the outside and forcing the resin to penetrate inside the block in all empty spaces that can be found under the liquid head, pushed by a pressure differential of about 1 Kg/cm2;inserting into the autoclave a positive pressure to force the resin, pushed by a further positive pressure that can be adjusted from 0.5 to 6 Kg/cm2, to complete the process without leaving any internal area that is not reached by the resin and continuously and visually checking through a suitable porthole and with witnesses placed on the plane of the block, or with an automatic mechanism, that the upper level of the liquid head being descending does not let any part surface, thereby allowing the air to seep with consequent failure of the operation and manually or automatically taking care of restoring a safety level of the liquid head above the block;leaving the autoclave under positive pressure for a necessary time to complete the impregnation operation, said time being variable according to a composition of the block and being longer when it is necessary to fill the spaces between two plane juxtaposed slabs in direct contact and afterwards taking back the autoclave to atmospheric pressure;letting harden or hardening the resin in the autoclave or outside the autoclave;freeing the block from the brackets and the structural panels and then cutting with a blade the impermeable sheet and the permeable sheet, completely freeing the perimeter of the block if the selected spacer element is formed of plastic sheets that cannot be glued;rotating the block by 90°, freeing the block also from the remaining base impermeable sheet and from the permeable sheet base, taking the block onto a machine with diamond wire or blade and cutting on an outside of the block about one centimeter for every face, normally to the layers, freeing the various composite panels, made independent by said cuttings on the perimeter because they are separated by the plastic sheet since the beginning;sending the composite panels to surface finish operations and to following workings.10. Process according to claim 9, wherein the upturning operations of the block are performed on a fixed upturning device next to which the block is moved and on which the block is then loaded for upturning and following handlings and workings.11. Process according to claim 1, further comprising, in succession, before inserting the block into an autoclave to be impregnated:if necessary, completely washing with high-pressure water the slabs of stone material, and heating said slabs at 50?60° C.;placing, on a process platform abutted on a plane and equipped with rows of threaded holes arranged on four sides of said platform towards a center to be adapted to different plan sizes of the stone slabs and the other slabs and layers, having available at least two rows of threaded holes on longitudinal sides and at least two on transverse sides, a base impermeable sheet, and, above it, a permeable sheet that, if composed of one sheet with projections, will have such projections arranged upwards, the sheets being centered with respect to the following assembly of slabs and layers, the basic sheet having increased sizes in length and width to afterwards allow structural welding to the sheet, the sheet having sizes that are equal to or slightly less than slabs and layers;horizontally assembling in succession, said layers composed of stone slabs, reinforcement sheet or nets, plastic separating sheet that cannot be glued, and slabs or sheets made of other materials, said layers being all prepared of same sizes in width and length and being longitudinally and transversally aligned in a same way;when assembling of the block has been completed with all the programmed layers, placing on vertical walls of said block a single perimetrical sheet of permeable material, or placing on said vertical walls four sheets of said permeable material, having measures in length that are shorter than the one for the walls that they are aimed to cover and measures in width that are equal or slightly greater than the height of the walls themselves, taking care, if said permeable sheet has projections, that the projections are oriented towards the block;afterwards wrapping the impermeable sheet around the perimeter of the block and joining with a liquid-tight and gas-tight joint the two ends of said sheet, said sheet having a width that is greater than the height of the block, to form a containing basin for the resins over the upper face of the block;approaching in contact with two longitudinal vertical walls of the block the structural panels, whose width is greater than a maximum height of the block that can be processed to allow containing the resins, taking care that their lower edge is lifted by some centimeters from the bearing plane of the process platform, using temporary shims, and then stiffly securing said panels against said block by brackets equipped with slots in their bearing base to the process platform to which said brackets are secured with screws into threaded holes that can be reached through the slot;performing the same operations to secure the structural head panels, that have the same width as of the longitudinal panels, corresponding to the highest block that can be processed, taking care of choosing a most suitable type of panel, as length, for covering a maximum possible distance between vertical walls placed against a long side of the assembled block, to avoid leaving areas of said impermeable sheet that are subjected to resist, without said sheet being supported by the head panels, to hydrostatic pressures generated by the resin that will be inserted into the block;joining with a liquid-tight or gas-tight joint a whole vertical perimeter of the impermeable sheet, that has been previously welded on itself at its extreme edges and the sheet arranged at the block base, mutually joining them, with an operation that is helped by the thickness of the panels that defines an equal operating horizontal distance with respect to the block and the related distance with respect to the bearing base on the platform of said longitudinal panels and the head panels that guarantees a vertical operating space, with a structural welding process, to close the impermeable envelope that is wrapped around the block on five faces, leaving it open on its top;if necessary, to contain the hydrostatic pressures, perimetrically supporting at the base of the block and on its four sides, the impermeable sheet, with stiff containment beams anchored to the process platform or to the brackets, and placed between said brackets and the perimeter of block to cover the space between the welding and the lower edge of the panels.12. Process according to claim 1, or with all assembling and following impregnating steps of said layers performed in a formwork composed of a bottom and four structural metallic rigid walls in which the liquid-tightness and gas-tightness is guaranteed by the structures themselves and by sealing gaskets arranged in mutually-screwed connection areas of said rigid metallic structures, said structures also performing a function of containing hydrostatic thrusts of the resin towards the outside and thrusts generated by pressure differentials that occur in rebalancing steps at the atmospheric pressure or the steps of inserting overpressures inside the autoclave, between the outside of the block closed by said four walls, the bottom, and the upper-placed fluid resin head, wherein consumption of impregnation resins is limited by a structure that is placed above the block after having ended its assembling, such structure being composed of a material whose specific weight is greater than a specific weight of the resin and globally heavy enough to win the hydrostatic resin thrust and being built with a sufficient thickness so that the resin cannot cover it on the top, said structure being built of a material to which the resin cannot stick on or being coated with a paint or another protection to which the resin cannot stick on, the structure as a whole being formed by a central square or rectangular part, said central part configured to be accurately lifted and transported onto the block through connections, to cover a majority of an upper face of the block, said structure being composed such that its lower face in contact with the block is equipped with projections in contact with the upper face of said block, such projections configured to allow a passing channeling for the resin with a reduced height, said structure forcing the inserted resin to be arranged in thickness equal to many centimeters in a perimeter corridor defined by its plan encumbrance and by a perimeter inside the impermeable sheet that is contained and supported by the structural containment panels, said structure being also equipped with a central through-hole and equipped with reference notches for a resin level, said reference notches allowing to visually evaluate said level, through an inspection porthole, and allowing to provide, with a command or a manual action, inserting further resin to avoid that an area of the upper face of the block is uncovered, making air penetrate inside the block and making the impregnation process fail.13. Process according to claim 12, wherein the resin level check is automatically performed, and consequently pumping of resin is automatically controlled when the level drops below a safety level, such level being checked through a floater, said floater being placed into a central hole, or, to avoid turbulence disturbances, being placed through a second dedicated hole, communicating, next to the upper face of the block, with the main center distance hole.14. Process according to claim 1, wherein the block is assembled with layers whose width and length are different from width and length of other layers, each layer or homogeneous group of said layers having a different size in width and/or length, with a same starting assembling reference in the block at an angle of 90°, each layer or homogeneous group of said layers compensating at the other one or two ends for a resulting missing thickness through shims, so that the block, at the end of its assembling, is a complete parallelepiped, with its six faces free from areas in which filling material is missing.
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