AN IMPROVED ROLLER

Abstract

 Abrasive roller (1) for processing products in mineral and/or synthetic material, composite or not, comprising a plurality of abrasive elements (2), superimposed and packed together, which are removably engaged by interlocking a central and internal support body (3) and/or to other mounting structure (4) which is associated with said support body (3); characterized in that it comprises shaped hooking means made in a single body with said support body (3) and/or with said mounting structure (4);
each abrasive element (2) shaped as a sector of an annulus comprises an internal edge (11) in which counter-shaped means (16) are obtained, mechanically engaged in a shape relationship in a removable manner with said shaped coupling means.

Description

[0001] The present invention relates to an improved abrasive roller for processing products in mineral and/or synthetic material, composite or not.

[0002] In particular, the roller according to the invention can be used for calibrating, roughing, smoothing, grinding, grinding, squaring and/or chamfering of products, preferably but not necessarily in the form of a slab, in natural stone materials, for example marble or granite or other natural stones, or agglomerates, for example in quartz agglomerate, or in synthetic or sintered stone, for example in porcelain stoneware, or other composite materials.

[0003] In particular, by calibration we mean the processing step of a plate, on the bottom and/or on the top, or other product, to eliminate any cutting and/or molding defects and/or prepare it so for the following steps.

[0004] As is known, the diamond tools used for processing stone products and the like are substantially constituted by a metal core, which axially has a hole or other type of attachment for connection to the spindle of an operating machine which rotates the tool itself.

[0005] The metal core is externally equipped with an abrasive material which consists of a layer or discs of a sintered product based on diamond powder. The metal core can have the shape of a disk or a roller, with cylindrical or even conical development.

[0006] More specifically, at present, the rollers for sizing/roughing in the production lines of slabs in natural stone materials, for example marble or granite or other natural stones, or agglomerates, for example in quartz agglomerate, or synthetic stone or sintered, for example in porcelain stoneware, or other composite materials, are generally of two types:

• rollers in which the abrasion teeth (or other abrasive part) are welded directly with the torch on the roller body; in particular, these tools are normally used in productions that do not require particular performance and where there is not much material to remove; conveniently, when the abrasive part is worn, the body remains which, if it is in good condition, can be advantageously reused;
• pack rollers (also called "disc pack rollers") in which the diamond abrasion teeth are welded onto rings/discs made of iron, aluminum or other alloys; the rings/discs thus arranged stacked on a cylindrical guide/support, which acts as a structural core, and are then packed all together using traditional flange systems; these rollers - which are more specific and expensive - have a very high removal capacity and a longer life than the version welded to the body, however, at the end of use, they are entirely and completely discarded.

[0007] Currently, the following phases are foreseen for the production of abrasive rollers:

1) phase of realization of the diamond abrasive support (in the shape of a tooth or other segment); in particular, through cold pre-molding of metallic and non-metallic powders, mixed with industrial and/or natural diamond powder, the abrasive support is created which is then sintered, with any process or through an uncontrolled pressure furnace or in a vacuum press furnace at a temperature compatible with the metal binder itself;

2) cleaning of the abrasive supports and preparation for welding; in particular, in this phase the previously prepared abrasive support is cleaned of any burrs, then passing to a radiusing (grinding) of the base of said support to make it adhere perfectly to the metal body where it will be welded; the final radius of the abrasive support is decisive because it must adhere as much as possible to the metal guide/support body, and this in order to avoid any detachment in the subsequent phases or during the use of the roller; furthermore, if a subsequent brazing phase is envisaged, the diamond supports must be aligned and wetted with a deoxidizing liquid which allows better adhesion results;

3) brazing or laser welding phase; in particular, after having prepared the abrasive supports, the latter can be welded to the metal body by:

a. brazing, which uses a brazing soft metal alloy interposed between the metal body and the diamond abrasive support, thus joining the two at medium-low temperatures (always lower than sintering); this welding technique is the most widespread among roller manufacturers and involves high costs for the brazing alloy (since it sometimes also contains silver) as well as particularly long production times (about 10 minutes for each ring/disc, considering that a roller has from 10 to 100 rings/discs the overall time required for this operation is particularly high); moreover, it is always important to check the alignment of the diamond parts of the supports (from right to left) as, if not well aligned, they could detach during use or worse still damage the material to be processed,

b. laser welding which is a technique that precisely - using a laser - fuses the base of the abrasive support with the end of the metal body; this technique is much faster (about 1 minute for each ring/disc), and therefore more productive, however it is particularly expensive (both in terms of the cost of the machine and of the electricity consumption required for laser welding) and moreover it is not compatible with all materials since, in order to carry out this type of welding, the abrasive support must be previously made with a metal binder compatible with the laser system itself; more in detail, in fact, this system cannot be applied to all metal alloys but only to those with a ferrous component inside; moreover, it is not possible to optimally weld a base of the abrasive support with the presence of diamond because the latter reflects the laser beam, thus making the welding non-compliant. To overcome this, the abrasive support is made with a base of binder, called "neutral" or "neutral foot", which is compatible with the laser and is diamond-free; this manufacturing process involves additional costs because more metal powders are used which are present on the two surfaces of the diamond abrasive support; moreover, in this welding phase the accuracy of the curvature of the base of the abrasive support is even more important since it is fused with the body and must adhere perfectly to the latter;

4) assembly phase which, in particular, is a fundamental and necessary phase for disc pack rollers; in more detail, during this phase, the operator must assemble the individual rings/discs and pay close attention to the relative position/rotation of the rings/discs since, making a mistake even by half a degree, means altering the shape of the helix by removing the residual material; in some cases it happens that, in the face of a macroscopic assembly error, the ring/disc rotates by a few degrees, thus completely closing the passage of the removal helix; currently, the operator uses glue to fix the ring/disc to the metal guide/support body, to prevent the rings/discs already positioned from making a relative rotation between them during assembly, however this manual fixing phase requires a long time (about 2 minutes per loop).

5) grinding phase to give the roller the final diameter and, moreover, "opens the diamond" making the cutting roller ready for work,

6) balancing phase to balance the roller and this is essential in order to have a balanced consumption of the roller itself and a regular removal of the material.

[0008] From documents US1850231, JPS57197464 and US6024635 an abrasive roller for processing metal objects, of cylindrical shape, rotatable around a central rotation axis, is known. The abrasive roller described therein is equipped with an external abrasive portion made by means of a plurality of inserts, each one connectable to a central support body, and externally define a cylindrical abrasion surface.

[0009] In particular, the inserts described in US1850231 are fixed to the central support body by interlocking screw heads screwed to the support body itself. Obviously, this provision carries with it the risk that these screws or bolts will loosen, affecting the functionality of the abrasive roller.

[0010] It is known from document WO2020/065689 the application of abrasive rollers on operating heads which carry mounted a plurality of said abrasive rollers, radially projecting starting from a central support body.

[0011] The object of the invention is to propose an abrasive roller for processing products in mineral and/or synthetic material, composite or not, which overcomes, at least in part, the aforementioned drawbacks present in traditional solutions.

[0012] Another object of the invention is to propose a roller which allows a regular and constant removal of material.

[0013] Another object of the invention is to propose a roller which allows to speed up its assembly and its preparation to make it ready for use.

[0014] Another object of the invention is to propose a roller that can be used in machines already available on the market.

[0015] Another object of the invention is to propose a roller which is an improvement and/or alternative to the traditional ones.

[0016] Another object of the invention is to propose a roller with an alternative characterization, both in constructive and functional terms, with respect to traditional solutions.

[0017] Another object of the invention is to propose a roller which can be manufactured simply, quickly and with low costs.

[0018] Another object of the invention is to propose a roller, whose construction, installation and maintenance are particularly simple, rapid and economical.

[0019] Another object of the invention is to propose a roller that can be easily configured and customized according to the specific needs of the customer and/or the application.

[0020] All these objects - considered both individually and in any combination thereof - are achieved, according to the invention, with a roller with the characteristics indicated in claim 1.

[0021] Further characteristics and advantages of the invention will become clearer from the description of the preferred embodiments, but non-exclusive, of the roller according to the invention, illustrated, purely by way of example and by way of non-limiting example, in the attached tables of drawings in which:

Figure 1

shows a perspective view of the supporting body of a first embodiment of the roller according to invention,

Figure 2

shows a front view of the support body of fig. 1,

Figure 3

shows the support body of fig. 1 according to section B-B of fig. 2,

Figure 4

shows in perspective view an abrasive element which can be mounted on the core of fig. 1,

Figure 5

shows in perspective view the roller of the first embodiment in which a plurality of abrasive elements of fig. 4 are mounted by sliding interlocking on the core of fig. 1,

Figure 6

shows an exploded perspective view of a second embodiment of the roller according to the invention,

Figure 7

shows the roller of fig. 6,

Figure 8

shows a side view of the roller of fig. 7 partially sectioned,

Figure 9

shows a perspective view of one of the abrasive elements of the roller of fig. 7,

Figure 10

shows an exploded perspective view of a third embodiment of the roller according to the invention,

Figure 11

shows the roller of fig. 10 partially sectioned,

Figure 12

shows a perspective view of one of the abrasive elements of the roller of fig. 10,

Figure 13

shows a side view of the abrasive element of fig. 12, and

Figure 14

shows the abrasive element of fig. 12,

Figure 15

shows the roller of fig. 10,

Figure 16

shows the roller of fig. 15,

Figure 17

shows the section C-C of fig. 16,

Figure 18

shows in perspective view a fourth embodiment of the roller according to the invention,

Figure 19

shows the roller of fig. 18,

Figure 20

shows the section D-D of fig. 19,

Figure 21A

shows in perspective view a fifth embodiment of the roller according to the invention,

Figure 21B

shows a cross section of the roller of figure 21A,

Figure 21C

shows in perspective view the support body of the roller of figures 21A and 21B,

Figure 21D

shows an exploded perspective view of the fifth embodiment of the roller,

Figure 21E

shows a perspective view of one of the abrasive elements of the roller of fig. 21A,

Figure 22A

shows in perspective view a sixth embodiment of the roller according to the invention,

Figure 22B

shows a cross section of the roller of figure 22A,

Figure 22C

shows an exploded perspective view of the sixth embodiment of the roller,

Figure 22D

shows in perspective view one of the abrasive elements of the roller of fig. 22A,

Figure 23A

shows in perspective view a seventh embodiment of the roller according to the invention,

Figure 23B

shows a cross section of the roller of figure 23A,

Figure 23C

shows an exploded perspective view of the seventh embodiment of the roller,

Figure 23D

is a perspective view of one of the abrasive elements of the roller of fig. 23A,

Figure 24A

shows in perspective view an eighth embodiment of the roller according to the invention,

Figure 24B

shows a cross section of the roller of figure 24A,

Figure 24C

shows an exploded perspective view of the eighth embodiment of the roller,

Figure 24D

shows in perspective view one of the abrasive elements of the roller of fig. 24A,

Figure 25A

shows in perspective view a ninth embodiment of the roller according to the invention,

Figure 25B

shows a cross section of the roller of figure 25A,

Figure 25C

shows an exploded perspective view of the ninth embodiment of the roller,

Figure 25D

shows in perspective view one of the abrasive elements of the roller of fig. 25A.

[0022] As can be seen from the figures, the abrasive roller according to the invention, indicated as a whole with the reference number 1, comprises a plurality of distinct abrasive elements 2 which are mounted so as to be removable both from each other and with respect to any support body 3 or mounting structure 4 which is associated with said body 3.

[0023] Conveniently, the abrasive elements 2 are mounted superimposed one on top of the other so as to form an element pack which thus defines the abrasive outer surface 5 of the roller 1.

[0024] In particular, the individual abrasive elements 2 are made separately and are assembled and superimposed to thus form the roller 1. More in detail, the abrasive elements 2 are superimposed along the longitudinal extension X of the roller which, suitably, corresponds (or is parallel) to the axis rotation of the roller itself.

[0025] Advantageously, the abrasive elements 2 of the roller 1 are fixed to each other and/or to the support body 3 and/or to said mounting structure 4 by means of a removable mechanical joint and/or by means of removable connection members so as to prevent their lateral movement.

[0026] Conveniently, in a preferred embodiment, the abrasive elements 2 are fixed to each other, or to the support body 3 or to the mounting structure 4, by means of a removable mechanical joint which is configured in such a way as to prevent their lateral movement, i.e. - in other terms - in order to prevent their movement along the circumferential development direction Y of the roller itself.

[0027] Preferably, the abrasive elements 2 are fixed to each other, or to the support body 3 or to the mounting structure 4, by means of removable connecting members, such as bolts, screws or rivets, so as to prevent their lateral movement, i.e. - in other terms - so as to prevent their movement along the direction of circumferential development Y of the roller itself.

[0028] In particular, as mentioned, the abrasive elements 2 can be removably fixed by interlocking and/or by means of removable connection members (for example screws, bolts or rivets) to each other and/or to a support body 3, in particular directly to a' internal central tubular core 6 for support, or to a mounting structure 4 with bars 7 which is integral with the central tubular core 6 or even to shaped discs 41 preferably interposed between the packs of abrasive elements 2.

[0029] Conveniently, each abrasive element 2 it comprises a corresponding laminar body or plate 8 (ie in which the thickness is less than the other two dimensions) substantially having the shape of a sector of an annulus.

[0030] Advantageously, each body shaped like a sector of an annulus 8 has a circumferential development less than at least half of the annulus resulting from the curvature of the corresponding sector, preferably it can be equal to or less than ¼ of said annulus and, even more preferably, it can be equal to or less than 1/8 of said annulus. Advantageously, this allows to reduce the overall dimensions before assembly of the roller itself (for example during the transport or storage phase), as well as allowing their easy and rapid replacement when they are worn or when a different hardness of the abrasive is required.

[0031] In a possible and preferred embodiment, the roller 1 according to the invention comprises a plurality of abrasive elements 2 which can have even different shapes, in particular the corresponding bodies of said elements shaped like an annular sector can have different circumferential extension of the corresponding sector of the annulus.

[0032] Preferably, all the abrasive elements 2 of the roller 1 - even if of different shapes - have in any case all the same means (ie the same among all the elements 2) for interlocking engagement with each other and/or with a central support body 3 and internal or other mounting structure 4 which is associated with said support body 2.

[0033] In another possible embodiment, the roller 1 according to the invention comprises a plurality of abrasive elements 2 which are all identical to each other, both in terms of shape and size, thus making them interchangeable.

[0034] In a possible and preferred embodiment, the roller 1 comprises (at least two) abrasive elements 2 which have different hardness from each other.

[0035] In a possible and preferred embodiment, the roller 1 comprises (at least two) abrasive elements 2 which are made with different material compositions.

[0036] In a possible and preferred embodiment, the roller 1 comprises (at least two) abrasive elements 2 which contain different abrasive materials and/or different percentages of abrasive materials.

[0037] In another possible embodiment, the roller 1 may comprise abrasive elements 2 which all have equal hardness, material composition and percentage of abrasive materials.

[0038] Conveniently, each abrasive element 2 can comprise:

• a mounting base that is designed for removable fixing by interlocking and/or by means of removable connection elements (for example screws, bolts or rivets) with other abrasive elements, and/or with the support body 3, and/or to another mounting structure 4 which is associated with said support body 2,
• an abrasive part that is designed for abrasion of the material.

[0039] Preferably, the mounting base can be the same in terms of shape or method of removable fastening between all the elements 2 of the roller 1.

[0040] In a possible and preferred embodiment, the roller 1 comprises (at least two) abrasive elements 2 with different shapes and/or surface development of the abrasive part.

[0041] In a possible and preferred embodiment, the roller 1 comprises (at least two) abrasive elements 2 with different heights of the abrasive part. Conveniently, while all the abrasive elements 2 are provided with a mounting base, some abrasive elements 2 could be devoid of the abrasive part or the latter could have a minimal development with respect to the corresponding mounting base.

[0042] Conveniently, each abrasive element 2 contains entirely or at least in part diamond parts/powders.

[0043] Conveniently, each abrasive element 2 is entirely made of abrasive material or comprises an abrasive layer at least in correspondence with its external profile.

[0044] Conveniently, each abrasive element 2 contains metal parts and diamond parts. Conveniently, each abrasive element 2 contains metal parts, non-metal parts and diamond parts.

[0045] Conveniently, each abrasive element 2 is made by sintering based on diamond powder or it can be made by 3D printing technologies, or it can be made according to other traditional production methods.

[0046] More in detail, each abrasive element 2 is made by cold pre-molding of metal and/or polymeric powders, mixed with industrial and/or natural diamond powder; suitably, the element thus pre-molded is then sintered on in an oven not controlled under pressure or in a vacuum press oven at a temperature compatible with the metal binder itself.

[0047] Conveniently, the roller 1 has attachment means 10 for connection to the mandrel (not shown) of an operating machine which rotates the roller. Preferably, these attachment means 10 comprise corresponding attachment seats spaced circumferentially and made on a closing counterflange 12, as described in more detail below, but they could also be made on the flange 13 of the support body 3.

[0048] Conveniently, if provided, the internal support body 3 has a tubular conformation with a central cavity 29 which extends along the X axis and inside which the spindle of the operating machine is inserted - at least partially - which causes the roller itself to rotate. Conveniently, the central cavity 29 of the internal support body 3 can have two areas with different diameters of the cross sections.

[0049] In a first embodiment (see fig. 1-3), on the external lateral surface of the support body 3, and in particular of the internal central tubular core 6, shaped grooves 14 are formed which, preferably, extend along the direction of longitudinal development X of the roller itself (and corresponding also to the longitudinal development direction of the body 3).

[0050] The roller 1 preferably comprises shaped hooking means made in a single body with said support body 3 and/or with the mounting structure 4.

[0051] Advantageously, each abrasive element 2 shaped like an annular sector comprises an internal edge 11 in which they are formed counter-shaped means 16 mechanically engaged in a relationship of form in a removable manner with said shaped coupling means. For example, the shaped coupling means can comprise said shaped grooves 14.

[0052] Conveniently, the shaped hooking means can be made for example by concavity or convexity of the support body 3 and/or of the mounting structure 4.

[0053] Preferably, the means of shaped hooks do not include screws, bolts or the like.

[0054] In this way, the assembly of the abrasive elements 2 on the support body 3 and/or on the mounting structure 4 is quick, simple and obviates the risk that any screws or bolts may loosen and affect the operation of the roller 1.

[0055] Suitably, each abrasive element 2 shaped like an annular sector comprises an internal edge 11 in which counter-shaped means 16 are obtained, in particular for sliding interlocking insertion into the shaped grooves 14 of the support body 3. Conveniently, the cross section of the shaped grooves 14 is substantially complementary to that of the counter-shaped means 16, to thus allow the insertion and engagement of the latter within said grooves.

[0056] More in detail, for example, these counter-shaped means 16 comprise "T" -shaped heads 16' which fit and slide inside corresponding "T" -shaped grooves 14.

[0057] Conveniently, the interlocking engagement of the counter-shaped means 16 of the abrasive elements 2 within the shaped grooves 14 of the support body prevents the lateral/circumferential translation of the elements themselves. Furthermore, the abrasive elements 2 are conveniently packed/superimposed on each other along the longitudinal development axis X of the roller itself, thus preventing any movement of the formerHHH also along this axis.

[0058] Conveniently, the abrasive elements 2 shaped like an annular sector are mounted by interlocking on the support body 3 so as to be superimposed/packed together and at the same time offset circumferentially so as to define at least one recessed profile along the abrasive outer surface of the roller. 15 for the removal/abrasion of the material. Preferably, said recessed profile 15 has an extension which is substantially helical, but could have another suitable geometry which is more suitable for the type of material to be abraded. In particular, this recessed profile 15 can develop diagonally and with steps between the two opposite ends 17', 17" of the roller.

[0059] Conveniently, the shaped grooves 14 are closed by an abutment flange 13 at one end of the support body 3, while they are open at the other end to allow the interlocking insertion and sliding of the counter-shaped means 16 of the abrasive elements 2. Conveniently, a closing counterflange 12 is also provided which is fixed by means of traditional fastening members - for example suitable bolts 27 - which engage in corresponding holes 28 obtained in the support body 3 at the open end, to thus keeping the transverse elements 2 packed and close together, once these have been assembled by interlocking on said support body 3.

[0060] In a second embodiment (see fig. 6-9), in correspondence with the external surface of the support body 3, a mounting structure 4 is provided which - preferably - comprises a plurality of bars 7 spaced apart and arranged around the support body (3) parallel to the longitudinal development direction X of the roller/body itself. In particular, the bars 7 on one side are integral with or abut with the extremal flange 13 of the support body 3 while on the other side they are integral with or abut with the closing counter-flange 12 which is advantageously fixed with traditional fastening means - for example by means of suitable bolts 27 - which engage in corresponding holes 28 made in the support body itself 3.

[0061] Conveniently, each abrasive element 2 shaped like an annular sector comprises, in correspondence with its inner edge 11, counter-shaped means 16 for the' sliding interlocking insertion of the bars 7 of the structure 4. More specifically, these counter-shaped means 16 comprise recesses 19 open towards the outside and configured (both in terms of size and shape) to circumferentially embrace said bars 7 beyond their diameter, in order to prevent their lateral movement.

[0062] Conveniently, in a version not shown here, the counter-shaped means 16 can comprise suitable holes with a closed profile to thus completely embrace the circumference of corresponding bars 7. In this case, the holes can be conveniently obtained inside the body of the abrasive element 2, ie without necessarily being open towards the inner edge 11 of said body.

[0063] Conveniently, each abrasive element 2 can comprise two or more recesses/holes for the insertion of corresponding bars.

[0064] In the third and fourth embodiment it is the abrasive elements 2 themselves which comprise, in addition to the counter-shaped means 16, also shaped members 20 configured to engage by interlocking with the counter-shaped means 16 of at least one other abrasive element 2. In particular, in this case, the support body 3 may not provided (see fig. 18-20 relating to the fourth embodiment) at all or, if provided, it may be devoid of shaped members for the interlocking engagement of corresponding counter-shaped means 16 of the abrasive elements (see fig. 10-17 relating to the third embodiment).

[0065] In particular, in this case, protruding portions (protuberances) 23 - which define said shaped members 20 - are provided on each abrasive element 2 shaped like an annular sector, in particular in correspondence with a face 22 of said element provided recessed or perforated portions 24 - which define said counter-shaped means 16 - within which the protruding portions 23 of at least one other abrasive element are engaged, which is superimposed on the first along the longitudinal extension X of the roller itself.

[0066] Conveniently, each abrasive element 2 comprises at least two protruding portions (protuberances) 23 and at least two hollowed or perforated portions 24.

[0067] Preferably, but not necessarily, the hollowed or perforated portions 24 can correspond to the recesses 19 described above in relation to the second embodiment.

[0068] Conveniently, also in this case, the interlocking engagement of the shaped members 20 of each abrasive element 2 with the counter-shaped means 16 of at least one other superimposed abrasive element 2 prevents the lateral/circumferential movement of the abrasive elements between them. Furthermore, also in this case, the abrasive elements 2 are conveniently packed/superimposed on each other along the longitudinal development axis X of the roller itself, thus preventing any movement of them also along this axis. Conveniently, the circumferentially adjacent abrasive elements 2 are spaced apart by a constant pitch, to thus define a hollowed profile 15 with a substantially helical development at the outer surface 5 of the roller.

[0069] Conveniently, in the third embodiment, corresponding protruding portions/protuberances 23 are fixed/obtained on the flange 13 of the support body and on the counterflange 12, which engage with the recessed/perforated portions 24 obtained in the corresponding facing abrasive elements 2,

[0070] in the fourth embodiment only the extremal flange 12 is provided, without the internal tubular part of the support body 3, and a containment counterflange 12 between which the abrasive elements 2 shaped like an annular sector are packed.

[0071] The roller 1 according to the invention comprises a plurality of abrasive elements 2 shaped like an annular sector and arranged together so as to form a plurality of corresponding annuli 30 overlapping and packed together, said abrasive elements 2 being engaged in a removable interlocking and/or by means of removable connection members (for example screws, bolts or rivets) to each other and/or to a central and internal support body 3 or to other mounting structure 4 which is associated with said support body 3. Conveniently, the entire pack of annuli 30 overlapping each other and in mutual contact - each of which is composed of a plurality of abrasive elements 2 shaped like a sector of said annulus - is kept packed and closed at the ends respectively by a flange 13 and by a counterflange 12 for closing/containment.

[0072] Conveniently, the circumferentially adjacent abrasive elements 2 are spaced apart by a constant pitch.

[0073] Conveniently, the circumferentially adjacent abrasive elements 2 are spaced apart by a constant pitch, to thus define a hollowed profile 15 with a substantially helical development for the removal of the removed material.

[0074] Conveniently, in the roller 1 according to the invention the abrasive elements 2 are not welded either to each other or to the internal and central support body 3 or other mounting structure 4. Basically, no welding of the abrasive elements 2 containing parts or diamond dust or other abrasive parts.

[0075] The abrasive elements 2 shaped like an annular sector are arranged circumferentially between them so as to define a corresponding annulus 30 and are superimposed on each other along the longitudinal extension X of the roller 1 so as to define along the external abrasive surface 5 of the roller itself at least one substantially helical hollow profile 15 for material removal. Conveniently, according to the circumferential arrangement of the abrasive elements 2, the substantially helical recessed profile 15 can have various possible designs.

[0076] Furthermore, the abrasive elements 2 which define the extremal annuli 30 of the roller (ie at the ends 17' and 17" ) abut respectively on the flange 13 (alone or fixed to the tubular core 6 of the support 3, if provided) and on the closing counterflange 12.

[0077] The present invention also relates to a kit for making an abrasive roller 1 comprising a plurality of abrasive elements 2, as described above, which are shaped like an annular sector and which advantageously, they all have the same removable fixing method by interlocking or by means of removable connection members (such as screws, bolts or rivets).

[0078] The present invention also relates to a method for mounting and manufacturing an abrasive roller 1 as described above. In particular, said method provides for the sequential arrangement of the abrasive elements 2 shaped like an annular sector one next to the other so as to define first a corresponding annulus 30 and then a plurality of annuli 30 superimposed on each other; suitably, moreover, the abrasive elements 2 which define each annulus 30 are spaced circumferentially from each other by a predefined pitch along the circumferential development of the corresponding annulus, to thus define a recessed profile 15 in correspondence with the abrasive external surface 5 of the roller 1.

[0079] Conveniently, during assembly (see first and second embodiments), the abrasive elements 2 can be associated by mechanical interlocking with the support body 3 or with a mounting structure 4 with bars 7 which is mounted on said support body.

[0080] Conveniently, during assembly (see third and fourth embodiments), the abrasive elements 2 of an annulus can be associated by mechanical interlocking with the abrasive elements 2 of the previously defined annulus.

[0081] Conveniently, during assembly, the abrasive elements 2 of an annulus can be associated by means of removable connecting members (for example screws, bolts, rivets):

• to support body 3, and/or
• to a mounting structure 4 with bars 7 which is mounted on said support body 3, and/or
• to the abrasive elements 2 of the annulus previously defined.

[0082] Advantageously, in accordance with the fifth embodiment (see 21A-21E), the mounting structure 4 comprises shaped discs 41 configured to engage said abrasive elements 2 in shape relationship.

[0083] Advantageously, the shaped discs 41 are interposed annuli 30 of abrasive elements 2 circumferentially adjacent.

[0084] Advantageously, said shaped disks 41 comprise protruding elements configured to engage said counter-shaped means 16 of said abrasive elements 2 in a proportional relationship.

[0085] Conveniently, each abrasive element 2 shaped like an annular sector comprises counter-shaped means 16 for sliding interlocking insertion in the shaped discs 41 of the structure 4. More in detail, these counter-shaped means 16 comprise side walls, preferably flared, configured (both in terms of size and shape) to engage said shaped discs 14 in shape relationship which define undercut seats, for thus preventing their lateral movement.

[0086] Conveniently, the shaped discs 41 of the structure 4 comprise seats 42 of substantially trapezoidal shape configured to house substantially to size, and at least partially, corresponding abrasive elements 2. In this way, the seats house the abrasive elements 2, preventing them from radial movement, in order to away from the central rotation axis.

[0087] In accordance with a sixth embodiment illustrated in the attached figures 22A-22D, the shaped discs 41 comprise protruding elements 43 configured to engage counter-shaped means 16 obtained on the internal wall 11 of each abrasive element 2. The protruding elements 43 project from the corresponding shaped disc 41 parallel to the rotation axis and/or to the direction of development X.

[0088] In particular, the counter-shaped means 16 preferably comprise seats which house the protruding elements 43.

[0089] In accordance with a seventh embodiment illustrated in the attached figures 23A-23D, the shaped discs 41 comprise housing seats 44, in particular made by removing material from the shaped discs 41, configured to engage counter-shaped means 16 obtained on the internal wall 11 of each abrasive element 2.

[0090] In particular, the counter-shaped means 16 suitably include suitable convexity and/or concavity developing radially with respect to the direction of development X, and engage the corresponding housing seats 44.

[0091] Conveniently, the counter-shaped means 16 engage the housing seats 44 of the shaped discs 41 in a shape relationship, with undercut locking.

[0092] Preferably, the abrasive elements 2 comprise an enlarged base 45, in correspondence with the internal wall 11, configured to house the counter-shaped means 16 and to engage the corresponding shaped disc 41. Conveniently, the enlarged base 45 of each abrasive element 2 is arranged adjacent to the enlarged base 45 of two contiguous abrasive elements, engaged to the same shaped disc 41.

[0093] In accordance with an eighth embodiment (see figures 24A-24D) and a ninth embodiment (see figures 24A-25D), similarly to the first embodiment, on the external lateral surface of the support body 3, and in particular of the internal central tubular core 6, shaped grooves 14 are formed.

[0094] Unlike the first embodiment, in accordance with the eighth embodiment, the shaped grooves 14, preferably, develop helically around the longitudinal development axis X of the roller itself (and also corresponding to the d direction of longitudinal development of the body 3).

[0095] Differently again, in accordance with the ninth embodiment, and similarly to the first embodiment, the shaped grooves 14 preferably develop parallel to the longitudinal development axis X of the roller itself (and also corresponding to the longitudinal development direction of the body 3).

[0096] Advantageously, in accordance with the ninth embodiment illustrated in the attached figures 25A-25D, the counter-shaped means 16 comprise "T" -shaped heads 16' which slide slidably into corresponding "T" -shaped grooves 14 of the body 3.

[0097] Furthermore, in accordance with the ninth embodiment, at least one closing counterflange 12 is also advantageously provided and preferably two counterflanges 12 which are fixed by means of traditional fastening members - for example suitable screws or bolts 27 - which engage in corresponding holes 28 obtained in the support body 3 in correspondence with the two respective open ends, to thus keep the abrasive elements 2 packed and close together, once these have been mounted by interlocking on said support body 3.

[0098] Preferably, the holes 28 for the engagement with the fixing members 27 are made on ribs of the support body 3, which define between them the shaped grooves 14.

[0099] Conveniently, each abrasive element 2 shaped like an annular sector comprises an internal edge 11 in which counter-shaped means 16 are formed for sliding interlocking insertion into the shaped grooves 14 of the support body 3. Conveniently, the cross section of the shaped grooves 14 is substantially complementary to that of the counter-shaped means 16, to thus allow the insertion and engagement of the latter within said grooves.

[0100] Conveniently, in particular in the embodiments of figures 21A - 21E, 22A - 22D, 23A - 23D, 24A - 24D, 25A - 25D, shaped hooking means made in a single body with said support body 3 and/or with said mounting structure 4; moreover, each abrasive element 2 - which is shaped like a sector of an annulus - comprises an internal edge 11 in which counter-shaped means 16 are obtained which are mechanically engaged in a shape relationship in a removable manner with said shaped hooking means.

[0101] In practice it has been found that the roller according to the invention fully achieves the intended aim, since the interlocking engagement of the abrasive elements, with each other and/or with the support body or with the mounting structure, allows to completely eliminate the welding step which, at present, is necessary to make both the body roller and the disk pack roller. Advantageously, by completely eliminating the welding phase, the following are eliminated:

• the need to prepare the neutral foot,
• the need to carry out a precision radiusing/bending of the abrasive element,
• the use of deoxidant,
• the positioning of the abrasive elements, on the body of the roller or on each disc, by the operator,
• all costs due to welding, costs which are particularly significant both in terms of time and management (ie about 25% of the cost of the roller itself).

[0102] Furthermore, another advantageous aspect of the solution according to the invention is the speed and simplicity of assembly, which makes the roller more economical and competitive. In fact, the roller according to the invention, being composed of a plurality of abrasive elements that fit together and/or to the support body and/or to the mounting structure, is particularly simple and quick to assemble and assemble, not requiring any glue and also eliminating any risk of misalignment and/or loss of the helix/spiral for removing the resulting material.

[0103] Furthermore, the speed and simplicity of assembly of the roller according to the invention advantageously allow the consumer/user to mount the roller autonomously, when he deems it more appropriate and by choosing the elements with the abrasives most suitable for the material to be abraded. In fact, another advantageous aspect of the roller according to the invention is that it can be composed of elements, preferably geometrically identical, but with different abrasive characteristics.

[0104] Furthermore, another advantageous aspect, deriving from the possibility for the user to self-assemble the roller according to the invention, is the considerable reduction in transport costs, in particular in the face of the reduced overall dimensions of the roller when it is disassembled/unassembled.

[0105] Conveniently, the abrasive roller according to the invention is suitable for processing products made of mineral and/or synthetic materials, composite or not.

[0106] In particular, the abrasive roller according to the invention can be used for calibrating, roughing, smoothing, grinding, squaring and/or chamfering of products, preferably but not necessarily in the form of a slab, in natural stone materials, for example marble or granite or other natural stones, or agglomerates, for example in quartz agglomerate, or in synthetic and sintered stone, for example in porcelain stoneware, or other composite materials.

[0107] In particular, by calibration we mean the processing step of a plate, on the bottom and/or on the top, or of other products, to eliminate any cutting and/or molding defects and thus prepare it/s for the following steps.

[0108] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept; moreover, all the details can be replaced by other technically equivalent elements.

[0109] In practice, the materials used, as well as the dimensions, may be any according to the requirements and the state of the art.

Claims

1. Abrasive roller (1) for processing products in mineral and/or synthetic material, composite or not, comprising a plurality of abrasive elements (2), superimposed and packed together, which are removably engaged by interlocking a central and internal support body (3) and/or to other mounting structure (4) which is associated with said support body (3);

characterized in that it comprises shaped hooking means made in a single body with said support body (3) and/or with said mounting structure (4);

each abrasive element (2) shaped as a sector of an annulus comprises an internal edge (11) in which counter-shaped means (16) are obtained, mechanically engaged in a shape relationship in a removable manner with said shaped coupling means.

2. Roller according to claim 1, characterized in that said abrasive elements (2) are shaped like an annular sector and are arranged together in such a way as to form a plurality of corresponding annuli (30) superimposed and packed together.

3. Roller according to one or more of the preceding claims, characterized that said plurality of abrasive elements (2) are shaped like an annular sector and at least two of said abrasive elements (2) have circumferential extension and/or hardness and/or composition of different material and/or percentage of abrasive.

4. Roller according to one or more of the preceding claims, characterized in that each abrasive element (2) consists of a laminar body or plate (8) which is shaped like an annular sector and has a circumferential development less than at least half of the annulus resulting from the curvature of said sector, preferably equal to or less than 1/4 of said annulus and, even more preferably, equal to or less than 1/8 of said annulus.

5. Roller according to one or more of the preceding claims, characterized in that the abrasive elements (2) circumferentially adjacent, and which thus define the same annulus (30), are spaced apart by a constant pitch, to thus define a hollow profile (15) for the removal of the removed material.

6. Roller according to one or more of the preceding claims, characterized in that it comprises a support body (3) with a plurality of shaped grooves (14) in correspondence with its external lateral surface and in that each shaped abrasive element (2) The annular sector comprises an inner edge (11) in which counter-shaped means (16) are obtained for sliding interlocking insertion into the shaped grooves (14) of the support body (3).

7. Roller according to one or more of the preceding claims, characterized in that it comprises a mounting structure (4) which is associated with the support body (3) and which is provided with a plurality of bars (7) arranged around said body support (3), and by the fact that each abrasive element (2) shaped as a sector of an annulus comprises counter-shaped means (16) for sliding interlocking insertion of said bars (7) of the mounting structure (4).

8. Roller according to one or more of the preceding claims, characterized in that on each abrasive element (2) shaped like an annular sector there are both shaped members (20) and counter-shaped means (16) within which the shaped members (20) of at least one other abrasive element which is superimposed on the first along the longitudinal extension (X) of the roller itself.

9. Roller according to one or more of the preceding claims, characterized in that said abrasive elements (2) are not welded together and also are not welded to the internal and central support body (3) or to other mounting structure (4), if any.

10. Roller according to one or more of the preceding claims, characterized in that said mounting structure (4) comprises shaped discs (41) configured to engage said abrasive elements (2) in a proportional relationship.

11. Roller according to the preceding claim, characterized in that said shaped discs (41) are interposed to circular rings (30) of abrasive elements (2) circumferentially adjacent to each other.

12. Roller according to the preceding claim, characterized in that said shaped discs (41) define said shaped seats (14), engaged by counter-shaped means (16) of said abrasive elements (2).

13. Roller according to one or more of claims 10 to 12, characterized in that said shaped discs (41) comprise protruding elements configured to engage said counter-shaped means (16) of said abrasive elements (2) in a proportional relationship.

14. Roller according to one or more of the preceding claims, characterized in that it comprises a support body (3) with a plurality of shaped grooves (14) in correspondence with its external lateral surface, in which said shaped grooves (14) develop helically around the longitudinal development axis X of said roller (1).

15. Method for making an abrasive roller (1) for processing products in mineral and/or synthetic material, composite or not, said method being characterized in that it uses a plurality of abrasive elements (2) shaped as a sector of annulus and by the fact that the abrasive elements (2) shaped like an annular sector are arranged in sequence one next to the other so as to define first a corresponding annulus (30) and then a plurality of annuli (30) overlapping each other.

Drawing