TECHNICAL FIELD
[001] The present disclosure relates to the field of providing reinforcement to marble blocks. More particularly, the present disclosure relates to a technique of sealing resin on the marble blocks along with the 3D material for improving the reinforcement of the marble blocks.
BACKGROUND
[002] Since availability of high quality marble blocks is decreasing, process of reinforcing the marble block is increasingly developing for amending the blocks with imperfections, to prevent slabs from breaking, during their cut in suitable required frames.
[003] The current technology of marble industry uses a resin application process where one layer of fiber glass using epoxy resin paste is applied on four sides of the block. This process has shortcomings such as the fibreglass is applied only on four sides of the marble block and has no penetration of the epoxy resin paste in cracks of the marble block. Due to the cracks remaining unfilled, block is susceptible to damages during their cut in sawing. Also, using this technique produces a low quality marble block and leads to safety hazards for an individual in subsequent operations.
[004] Another technique of applying the resin material to the marble block uses a vacuum resin process using a draining layer and a fiber glass. This technique suffers from limitations such as being expensive, low speed of infusion, and is a delicate process with high possibility of mistakes leading to breakage of the marble block, and is labour intensive.
[005] Yet another technique for repairing and consolidating a parallelepiped stone block is available. This technique requires applying a sheath around the marble block that is higher than the block and is spaced from the block by means of suitable spacers or fabric material. The sheath has its upper side open and is filled with resin. The marble block with the sheath is put in an autoclave and filled with resin under vacuum. This process is very expensive, and requires an autoclave and a framework made around the sheath. Also, this technique requires a high amount of resin.
[006] Thus, there is a need to provide an inexpensive and extensive technique where 3D material is applied on the marble blocks along with a resin hardener for reinforcement of strength of the marble block. 2
OBJECTS OF THE PRESENT DISCLOSURE
[007] A general object of the present disclosure is to seal resin on marble blocks along with a 3D material to penetrate resin in all interconnected cracks for improving strength reinforcement of the marble blocks.
[008] Another object of the present disclosure is to provide the resin flow that is fast regardless of a vacuum condition with the use of 3D material.
[009] Another object of the present disclosure is to provide the 3D material that replaces a draining layer and a fiber glass fabric layer. It also provides an excellent resin flow and good mechanical properties of the block.
[0010] Another object of the present disclosure is to provide the 3D material that is easily drape able around the marble block while maintaining intact the resin flow and mechanical properties.
SUMMARY
[0011] The present disclosure relates to a technique of sealing resin on marble blocks along with 3D material for improving reinforcement of the marble blocks.
[0012] An aspect of the present disclosure relates to a method for improving strength of a marble block, said method comprising: preparing a wooden base by using a two wooden plank supports; placing a layer of a vacuum bag over the wooden base, where pillows are applied inside and outside of the vacuum bag at the wooden plank supports; placing a layer of a 3D fiberglass over the layer of vacuum bag; placing the marble block over the layer of the 3D fiberglass; wrapping the marble block with the 3D fiberglass; placing a polyethylene (PE) spiral wrap pipe around wrapped marble block for flow of resin from base of the marble block along entire surface of the marble block, where the 3D fiberglass works as a structural flow media for the resin and also provides glass reinforcement to the marble block; covering the wrapped marble block with the vacuum bag and closing the vacuum bag by a mastic sealant; connecting the bag to a vacuum device by connecting a suction pipe of the vacuum device to an airtight adaptor located at top of the vacuum bag for realizing vacuum conditions inside the bag; connecting a resin flow pipes of a mixer device for infusing the resin through an airtight adaptors located at bottom of the bag; disconnecting the vacuum device upon the resin becoming hard and removing the vacuum bag to extract a resin coated marble block.
[0013] According to an embodiment, the wooden plank supports are placed separately according to a size of the marble block. 3
[0014] According to an embodiment, the pillows are made of a breather tissue.
[0015] According to an embodiment, the pillows are applied inside and outside of the vacuum bag at the wooden plank supports to protect the vacuum bag from accidental damage while placing the marble block on it.
[0016] According to an embodiment, the 3D material ensures flow and rise of the resin so to cover the entire marble block in the vacuum bag.
[0017] According to an embodiment, the infusion of the resin is based on fluidity of the resin and 3D fiberglass as internal flow media.
[0018] According to an embodiment, the vacuum conditions are maintained inside the vacuum bag until complete dryness of the resin.
[0019] According to an embodiment, the mixer device mixes an epoxy and a hardener in suitable proportions for creating a resin.
[0020] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0022] FIG. 1 illustrates exemplary implementation showing a wooden base created using wooden plank supports in accordance with embodiments of the present disclosure.
[0023] FIG. 2 illustrates exemplary implementation showing pillows being placed over the wooden plank supports in accordance with embodiments of the present disclosure.
[0024] FIG. 3 illustrates exemplary implementation for placing a vacuum bag sheet over the pillows and the wooden base in accordance with embodiments of the present disclosure.
[0025] FIG. 4 illustrates exemplary implementation for placing the pillows over the vacuum bag at the wooden plank supports in accordance with embodiments of the present disclosure. 4
[0026] FIG. 5 illustrates exemplary implementation for placing a 3D material sheet over the vacuum bag sheet in accordance with embodiments of the present disclosure.
[0027] FIG. 6 illustrates a mixer device and a vacuum device in accordance with embodiments of the present disclosure.
[0028] FIG. 7 illustrates exemplary implementation for placement of the marble block over the vacuum bag in accordance with embodiments of the present disclosure.
[0029] FIG. 8 illustrates exemplary implementation for the marble block being covered by the3D fiberglass in accordance with embodiments of the present disclosure.
[0030] FIG. 9 illustrates exemplary implementation for installing a PE spiral pipe around the marble block for injecting the resin in accordance with an embodiment of the present disclosure.
[0031] FIG. 10 illustrates exemplary implementation for showing connection of a suction pipe of the vacuum apparatus to an airtight adaptor located at top of the vacuum bag and connection of a pipe to the mixer for mixing and injecting the resin to an airtight adaptor located in lower portion of the vacuum bag.
DETAILED DESCRIPTION
[0032] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0033] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0034] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0035] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates 5
otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0036] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.
[0037] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0038] All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification 6
should be construed as indicating any non-claimed element essential to the practice of the invention.
[0039] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0040] The present disclosure relates to a technique for sealing resin along six walls of marble blocks along with a 3D material for improving stone reinforcement of the marble blocks.
[0041] An aspect of the present disclosure relates to a method for improving strength of a marble block, said method comprising: preparing a wooden base by using a two wooden plank supports; placing a layer of a vacuum bag over the wooden base, where pillows are applied inside and outside of the vacuum bag at the wooden plank supports; placing a layer of a 3D fiberglass over the layer of vacuum bag; placing the marble block over the layer of the 3D fiberglass; wrapping the marble block with the 3D fiberglass; placing a polyethylene (PE) spiral wrap pipe around wrapped marble block for flow of resin from base of the marble block along entire surface of the marble block, where the 3D fiberglass works as a structural flow media for the resin and also provides glass reinforcement to the marble block; covering the wrapped marble block with the vacuum bag and closing the vacuum bag by a mastic sealant; connecting the bag to a vacuum device by connecting a suction pipe of the vacuum device to an airtight adaptor located at top of the vacuum bag for realizing vacuum conditions inside the bag; connecting a resin flow pipes of a mixer device for infusing the resin through an airtight adaptors located at bottom of the bag; disconnecting the vacuum device upon the resin becoming hard and removing the vacuum bag to extract a resin coated marble block.
[0042] According to an embodiment, the wooden plank supports are placed separately according to a size of the marble block.
[0043] According to an embodiment, the pillows are made of a breather tissue.
[0044] According to an embodiment, the pillows are applied inside and outside of the vacuum bag at the wooden plank supports to protect the vacuum bag from accidental damage while placing the marble block on it.
[0045] According to an embodiment, the 3D material ensures flow and rise of the resin so to cover the entire marble block in the vacuum bag. 7
[0046] According to an embodiment, the infusion of the resin is based on fluidity of the resin and 3D fiberglass as internal flow media.
[0047] According to an embodiment, the vacuum conditions are maintained inside the vacuum bag until complete dryness of the resin.
[0048] According to an embodiment, the mixer device mixes an epoxy and a hardener in suitable proportions for creating a resin.
[0049] The technical benefits achieved by the implementation of various embodiments of the present disclosure are as recited below:
[0050] The present disclosure solves the above recited and other available technical problems by applying a 3D fiberglass material along the surfaces of the marble block for insulating the marble block against cracks and reinforcing the marble. The present disclosure relates to a method for improving strength of a marble block, said method comprising: placing a layer of vacuum bag over a wooden base; placing a layer of 3D fiberglass over the layer of vacuum bag; placing the marble block over the layer of the 3D fiberglass, and wrapping the marble block with the 3D fiberglass; applying a polyethylene (PE) spiral wrap pipe at the wrapped marble block for flow of resin from base of the marble block along entire surface of the marble block, where the 3D fiberglass works as a structural flow media for the resin and also provides glass reinforcement to the marble block; covering the wrapped marble block with vacuum bag; connecting a suction pipe of a vacuum device to an airtight adaptor located at top of the vacuum bag for realizing vacuum conditions inside the bag, and connecting a resin infusing pipe of a mixer device to an airtight adaptor located at bottom of the vacuum bag for injecting the resin to wrapped marble block.
[0051] FIG. 1 illustrates exemplary implementation showing a wooden base created using wooden plank supports in accordance with embodiments of the present disclosure, 100.In an embodiment, a wooden base can be created using two or more of the wooden planks, 102 that are placed apart based on the size of the marble block to be placed over the wooden planks.
[0052] FIG. 2 illustrates exemplary implementation showing two or more of pillows being placed over the wooden plank supports in accordance with embodiments of the present disclosure, 200. In an embodiment, the pillows 202 are made up of a material such as but not limited to a breather tissue.
[0053] FIG. 3 illustrates exemplary implementation for placing a vacuum bag sheet over the pillows and the wooden base in accordance with embodiments of the present 8
disclosure, 300. In an embodiment, the vacuum bag sheet, 302 is laid over above the prepared base. The vacuum bag sheet 302 is kept open with its wall let down. In an embodiment, the vacuum bag sheet is made of material such as but not limited to a flexible film made from sheets of polyolefin and nylon blend. In an embodiment, both the vacuum bag sheet and a 3D material sheet are laid onto the base, for the marble block to be placed over it.
[0054] FIG. 4 illustrates exemplary implementation for placing the pillows over the vacuum bag at the wooden plank supports in accordance with embodiments of the present disclosure, 400.In an embodiment, the pillows, 402 are placed inside and outside of vacuum bag.
[0055] FIG. 5 illustrates exemplary implementation for placing the 3D material sheet over the vacuum bag sheet in accordance with embodiments of the present disclosure, 500.In an embodiment, the 3D material sheet, 502 is laid over the vacuum bag sheet. In an embodiment, the 3D material sheet, 502 can be made of material such as but not limited a fiberglass. In an aspect of the disclosure, use of the 3D fiberglass material helps solve two purposes: 1) the fiberglass can be used as an internal flow media for an epoxy resin and 2) the 3D fiberglass material can provide for the fiberglass reinforcement with high mechanical properties. In an aspect, the 3D material has fast flowing capacity and hence easily permits flow of the epoxy resin from base of the marble block to top of the block and ensures complete spread of the resin over all surfaces of the marble block.In an aspect, a specific epoxy resin for the marble block’s impregnation and the marble block infusion can be chosen according to the kind of stone to resin or the color of the marble and granite to revive.
[0056] FIG. 6 illustrates the mixer device and the vacuum device in accordance with embodiments of the present disclosure, 600. In an embodiment, the mixer device, 604 is used to mix the hardener and a epoxy resin to obtain the resin to be applied to the marble block. In an embodiment, the vacuum device, 602 is used to create a vacuum condition inside the vacuum bag. The creation of the vacuum helps ensure complete spreading of the resin to cover all surfaces of the marble block. In an embodiment, the vacuum condition ensures complete elimination of presence of air even in smallest pores of the marble block and ensures high penetration of the resin. In an embodiment, the vacuum device ensures creation of vacuum degree so that of all interconnected cracks on the marble blocks and the 3D glass fiber sheet be filled with the resin. This ensures providing perfectly cohesive marble blocks after hardening of the resin. In an aspect, upon the vacuum device being activated, the device can perform within a vacuum degree in range of but not limited to -0.8 bar to -1.0 bar. 9
[0057] FIG. 7 illustrates exemplary implementation for placement of the marble block over the vacuum bag in accordance with embodiments of the present disclosure, 700. FIG. 8 illustrates exemplary implementation for the marble block being covered by the 3D fiberglass sheet, 502 in accordance with embodiments of the present disclosure. FIG. 9 illustrates exemplary implementation for installing a PE spiral pipe around the marble block for injecting the resin in accordance with an embodiment of the present disclosure, 900. In an embodiment, the wrapped marble block has the polyethylene (PE) spiral pipe laid around its surface. In an aspect, the PE pipe can be used for injecting the resin into the vacuum bag. In an aspect the pipes and the adaptors are placed for connecting the suction pipe of the vacuum device and connecting flow pipes for infusion of the resin. The present disclosure relates to a method for improving strength of a marble block, said method comprising: placing a layer of vacuum bag over a wooden base; placing a layer of 3D fiberglass over the layer of vacuum bag; placing the marble block over the layer of the 3D fiberglass, and wrapping the marble block with the 3D fiberglass; applying a polyethylene (PE) spiral wrap pipe at the wrapped marble block for flow of resin from base of the marble block along entire surface of the marble block, where the 3D fiberglass works as a structural flow media for the resin and also provides glass reinforcement to the marble block; covering the wrapped marble block with vacuum bag; connecting a suction pipe of a vacuum device to an airtight adaptor located at top of the vacuum bag for realizing vacuum conditions inside the bag, and connecting a resin infusing pipe of a mixer device to an airtight adaptor located at bottom of the vacuum bag for injecting the resin to wrapped marble block.
[0058] In an aspect, use of the PE spiral wrap pipes ensures homogeneous spreading of the resin. The adaptors are placed at top side of the block for suction piping and near base for resin infusion. In order to facilitate and make spreading of the resin process more uniform, two or more adopters are placed.
[0059] FIG. 10 illustrates exemplary implementation for showing connection of a suction pipe of the vacuum apparatus to an airtight adaptor located at top of the vacuum bag and connection of a pipe to the mixer for mixing and injecting the resin to an airtight adaptor located in lower portion of the vacuum bag.
[0060] In an embodiment, the marble block covered with the 3D fiberglass and with relative piping connection is wrapped in the vacuum bag. The vacuum bag is sealed with mastic sealant at joints to create air tight sealed spaces. 10
[0061] In an embodiment, the suction pipe is placed at top side of the marble block, 1002 and is connected to the vacuum system. The piping near the base of the marble block, 1004 is connected to the mixer system.
[0062] In an aspect, upon the vacuum system being activated the vacuum bag and the 3D fiberglass material perfectly adheres to irregular surface of the marble block.
[0063] In an aspect, the marble block is then placed in the vacuum condition for a specific time period to let the moisture evaporate and reach a best vacuum degree.
[0064] In an aspect, the flow of the resin in the marble block is initiated by infusing the resin into the marble block. The resin flows from base to top through 3D fiberglass present between the marble block and the vacuum bag.
[0065] In an aspect, the infused resin creates a uniform layer around the marble block and fills in all cavities, cracks and pores of the marble block.
[0066] In an aspect, upon the resin being dried a marble block perfectly made cohesive by the resin and covered with the 3D fiberglass saturated with resin is obtained.
[0067] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
ADVANTAGES OF THE PRESENT DISCLOSURE
[0068] The present disclosure provides a method for sealing resin on marble blocks along with the 3D material for improving strength of the marble blocks.
[0069] The present disclosure provides a method where the resin flow with 3D material is up to twice as fast as comparable to a draining layer and fiberglass layer. Also the flow properties of the resin are very good regardless of vacuum level.
[0070] The present disclosure provides a method where the 3D material replaces the draining layer and a fiberglass fabric layer and provides uncompressible layers with excellent resin flow which helps save a tremendous amount of time, money, labour and handling cost.
[0071] The present disclosure provides an efficient and fast method wheretwo separate operations i.e. initially covering the marble block with the layer of fiberglass fabric, 11
and then covering with a draining layer is replaced by a single operation i.e.covering the marble block with the 3D glass material.
[0072] The present disclosure is to provide a method for providing the 3D material that is easily drape able around the marble block while maintaining intact the resin flow and mechanical properties.
[0073] The present disclosure provides a method for making the fragile brittle marble blocks structurally sound.
[0074] The present disclosure provides a method for creating slabs out of the marble blocks that were considered too fragile for effectively processing into slabs.
[0075] The present disclosure provides a method for creating resin-treated marble blocks that offer a safer work environment during a sawing process, and help obtain finished slabs that are more consistent.

We Claim:
1. A method for improving strength of a marble block, said method comprising:
placing a layer of vacuum bag over a wooden base; placing a layer of a 3D fiberglass over the layer of vacuum bag; placing the marble block over the layer of the 3D fiberglass, and wrapping the marble block with the 3D fiberglass; placing a polyethylene (PE) spiral wrap pipe around wrapped marble block for flow of resin from base of the marble block along entire surface of the marble block, where the 3D fiberglass works as a structural flow media for the resin and also provides glass reinforcement to the marble block; connecting a suction pipe of a vacuum device to an airtight adaptor located at top of the vacuum bag for realizing vacuum conditions inside the bag, and connecting a resin infusing pipe of a mixer device for injecting the resin to wrapped marble block.
2. The method as claimed in claim 1, wherein the vacuum device is disconnected upon the resin becoming hard and removing the vacuum bag to extract a resin coated marble block.
3. The method as claimed in claim 1, wherein the method further comprises the step of covering the wrapped marble block with the vacuum bag, and closing the vacuum bag by a sealant and connecting the vacuum bag to the vacuum device
4. The method as claimed in claim 1, wherein the method further comprises the steps of
preparing the wooden base by using two wooden plank supports; and applying the pillows inside and outside of the vacuum bag at the wooden plank supports.
5. The method as claimed in claim 4, wherein the pillows are made of a breather tissue.
6. The method as claimed in claim 1, wherein the 3D material ensures flow and rise of the resin so to cover the entire marble block in the vacuum bag.
7. The method as claimed in claim 1, wherein the infusion of the resin is based on fluidity of the resin and 3D fiberglass as internal flow media.
8. The method as claimed in claim 1, wherein upon the resin rising from the base of the marble block to the top all gaps of cavities, cracks and pores present on the marble block are filled. 13
9. The method as claimed in claim 1, wherein the vacuum conditions are maintained inside the vacuum bag until complete dryness of the resin.
10. The method as claimed in claim 1, wherein the mixer device mixes an epoxy material and a hardener material in suitable proportions for creating the resin.