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Seamless Countertop Processing Technology

Last updated May 02, 2018

The Basic Process Flow of Seamless Countertop Processing
The production of a single process → selection of materials → cutting board → set thickness → bonding → basin hole and the processing of the throat hole → edging forming → polishing → layout processing → inspection → packaging storage
1, The Production of a Single Process
Although the processing technology of the countertops in stone processing is relatively simple, it is difficult to ensure that the processed countertops meet seamless requirements if there is no special processing guide for the processing.

2, The Choice of Materials
The material quality of the deck is very high. Granite and quartz stone must not be broken; Marble, artificial granite, pure white, imitation onyx and non-patterned stone are not allowed to be repaired; other marble and artificial granite stone should be reinforced and reinforced on the back. After there is no obvious trace of reinforcement, the surface of the artificial stone platform panel must not contain pits, holes, and sand holes, otherwise it will be easy to hide dirt and water, affecting the quality of the panel surface.
3, Cutting Board
1.1) When cutting the board, care must be taken to avoid various defects of the stone and avoid cracks, dark spots, color lines, stains, sweeping flowers, powder lines, bees, and severe yin and yang.
1.2) Control the cutting geometry, angle dimension, and diagonal dimension when cutting the board to be accurate.
1.3) Control the quality of the board surface when cutting, do not allow collapse, falling angle phenomenon. If the back of the table panel needs to be adhered, the edges, edges, and corners of the back panel must be intact to ensure the quality of processing after adhesion and polishing.
1.4) When cutting the board, pay attention to the difference in color and texture between the previously cut material and the currently cut material, especially the difference between the same set of table tops.
1.5) In order to ensure that the seams of the adhesive strips and the countertops meet the requirements of seamless quality, for some materials that cannot be avoided due to chipping or chipping, an allowance of 3 to 5 mm can be added to the side where the adhesives are adhered or the thickness can be determined. 2mm way to eliminate collapse, collapse phenomenon. Adhesion in the longitudinal direction can be added in the width direction of 3 ~ 5mm; width direction adhesive edge, in the length direction of 3 ~ 5mm margin. After adhering to the edges, remove the stickiness by edging or trimming.
1.6) Plate size standard for countertops: length (0, -1); width (-3, 3); thickness (-1, 1). For some countertops with furniture, special attention must be paid to the control of the cutting board's dimensional accuracy.
4, Set The Thickness
The purpose of setting the thickness is to eliminate the collapse of the underside of the deck. The quality of the fixed thickness determines the quality of the seamless deck. The thickness of the fixed thickness is based on the condition of the bottom edge collapse, and the width is preferably greater than the thickness or width of the adhesive strip.
When setting the thickness at the bottom edge, it is necessary to pay attention to the electroplating milling wheel. This is because the electroplated milling wheel is flatter than the face set by the sintered milling wheel, and the surface has no arc surface phenomenon.

When the thickness is set, it is necessary to control the running speed of the machine tool so as to prevent the occurrence of the phenomenon of low milling during the feeding of the thickness and the exit of the knife. The leveling control of the fixed thick surface should be less than 0.5mm/m to ensure that the adhesive seam is below 0.5mm.

Man Made White Marble Slab

5, Glued
The bonding process is a key process in the seamless countertop processing, which determines the size of the bonding seam, the color quality of the adhesive, and whether the countertop eventually achieves a seamless effect.
6.3 basin hole forming, drilling water hole.
The molding of the basin holes is more complicated than the molding of the sides. Taichung hole molding has convenient manual edging machine, universal machining center, Tenglong edging machine, hand-grinding machine, manual molding.
The water jet machine digs basin holes and hose holes. Basin hole, throat size standard 0 ~ +1. Such as the basin hole to be polished, waterjet machine processing, the size standard is -1 ~ 0.
6, Edge Molding
Edge molding is to process a certain edge of the table panel into various geometric shapes according to the production and processing orders. The common side is a large bevel edge, a large round edge, the French edge, the edge of the sea and so on.
The molding of the edges is now basically mechanized, and even the grinding and polishing are mechanized. The molding of countertop shaped plates can use engraving machines, special-shaped countertop molding machines, universal machining centers and portable edgers. However, the special-shaped platen panel can only be polished with a universal machining center. Because the price of the device is too high, the polishing of the special-shaped platen panel is mainly manual polishing.
7, Countertop Edge Polishing
The polishing of the table top is still dominated by hand-polished polishing, especially the special-shaped countertops. When the panel is polished, the operator polishes and examines the quality of the adhesive joint. If the glue seam is large and the color of the glue is not correct, do not continue to polish it. Rework the defective rejecting adhesive process, and then polish and polish the joint after it has been processed. During the grinding and polishing process, it is found that there is glue leakage in the glue joints, and the glue leakage area is filled with glue. Must not be polished after the completion of plastic repair, or make up the glue and then re-polished.
During the grinding and polishing process, the operator should observe whether the used grinding pieces will fade and will not contaminate the joints. If this happens, replace the grinding discs in time.

polishing process
8, The Board Surface Treatment
There are many processes in the processing of the panel. The surface of the panel is easily scratched and corroded by the circulating water used in the polishing and polishing, especially for black, dark stone and artificial granite. The board surface quality of the countertop is a product that is carefully inspected by the customer during the inspection. Therefore, the inspection personnel must carefully inspect the board surface quality of the countertop before seamless inspection. The quality of the surface inspection cannot reach the luminosity. It is also required to re-polishing and polishing to increase the brightness, or to polish the surface with polishing aids. Corrosion of the surface of the board must be cleaned with oxalic acid and clean water. The electric mill + wool felt is used to polish the boards until the corrosion marks on the stone board are removed.
9, Product Standards, Inspection
A, size standard, inspection
a, Thickness of the plywood thickened panel: (-3, 3)
b, No panel thickness (-1, 1)
c, Length dimension deviation (-1, 0); Width dimension deviation (-1, +1)

Inspection countertopl thickness dimension
B. Board quality inspection
a, Front, back inspection of the board: It requires clean, without any offset, dust, dirt.
b, No stone defects, wear marks, scratches, watermarks and other shortcomings.
c, No cracks, especially granite, quartz, artificial stone is not allowed to crack.
d, Warp deformation is not allowed and the flatness deviation is controlled within 1mm/m.
e, Photometry ≥90°, and the board surface is clear and crystal clear.

Detect flatness of the countertop
C, adhesive edge inspection
a, The gap is controlled within 0.5mm. The color of the seam is basically the same as the color of the board surface. The distance is 0.5m and the seam is invisible.
b, There is no dirt in the seam and it is yellow, and the adhesive glue is full and there is no glue leakage.
c, The seam cannot have the shape of the fold line and must be straight.
d, Adhesive strips have no obvious fractures, and if they are broken, they must be repaired to be inconspicuous.
e, The corner joints are glued with a cut of 45° and bottom. If you want to stick directly to the side of the deck, do not put it on the front of the deck.
f, Adhesive edges are too high and should be reinforced with Hercules glue at the intersection of the back of the deck and the adhesive strip.
D. Inspection of Shaped Plates and Shaped Edges
a, Deviation of ±1mm from standard shape of countertop shaped plate.
b, Shape deviation ± 1mm.
E. Face and throat examination
Basin hole, throat size standard 0 ~ +1.
F, complete inspection
For panels with a splicing relationship consisting mainly of sleeves, the inspectors shall test the entire set of drawings according to the installation plan. The two pieces of splicing shall be seamless; the splicing direction shall be marked for the splicing direction.
For a panel with a splicing relationship, the number and arrow must be marked on the back or side of the panel, and the number should be 5 mm from the panel surface.
Special-shaped board table and board must all test the outer contour of the panel, and also have a splicing relationship.
10, Packaging
During packaging, the product is packaged according to the customer's requirements or stone quality. The back and the back are opposite, and a soft foam film that prevents scratches is placed between the glossy surfaces, or the back skin, plastic film, and EPE are packaged. As for some fear of scratching stone, in order to prevent the appearance of scratches will be coated. Table panels should be placed vertically, so that the longitudinal force of the stone, do not horizontally, it is best to use the strap to tie all the table into a whole, can not be loose.

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