CN107107538A - 用于形成面板的套件以及形成面板的方法 - Google Patents

用于形成面板的套件以及形成面板的方法 Download PDF

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CN107107538A
CN107107538A CN201580053797.4A CN201580053797A CN107107538A CN 107107538 A CN107107538 A CN 107107538A CN 201580053797 A CN201580053797 A CN 201580053797A CN 107107538 A CN107107538 A CN 107107538A
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panel
body layer
side edge
external member
surface lamella
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K·奇力亚克里斯
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Wright Stone Holdings Ltd
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Wright Stone Holdings Ltd
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    • B32B7/02Physical, chemical or physicochemical properties
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
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    • E04F13/144Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of marble or other natural stone
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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)
  • Finishing Walls (AREA)

Abstract

一种用于形成面板的套件,包括面板部件,面板部件包括表面片层和本体层,表面片层由第一材料形成,表面片层粘附至本体层,表面片层大致平行于本体层,其中,本体层的厚度大于表面片层的厚度,本体层的密度小于表面片层的密度,且面板部件包括适于沿面板部件的至少一个边缘粘附的侧缘部分。

Description

用于形成面板的套件以及形成面板的方法
技术领域
本发明涉及一种用于形成面板的套件以及一种形成面板的方法。更具体但非排他地,本发明涉及一种意于作为石英石、大理石或花岗石实心面板替代物的轻量面板。
背景技术
已知使用石英石、大理石或花岗石实心面板用于诸如台面和包层之类的不同目的。由于它们的外观和触感,这些面板是令人期望的,但重量却非常重。
申请人已确认,这些面板的重量重是许多引起伤害甚至死亡的职业健康和安全(OHS)问题/索赔的原因。申请人还已确认,实心面板的重量重显著增加了这些面板的进口、加工和安装成本。
本发明的示例力求提供一种改进的面板,该面板克服了或至少减轻了与现有实心面板相关的缺点。
发明内容
根据本发明的一方面,提供有一种用于形成面板的套件,该面板包括面板部件,
面板部件包括表面片层和本体层,表面片层由第一材料形成,表面片层粘附至本体层,表面片层大致平行于本体层,其中,本体层的厚度大于表面片层的厚度,本体层的密度小于表面片层的密度,以及
分离的侧缘部分,该分离的侧缘部分适应于沿面板部件的至少一个边缘粘附。
优选地,侧缘部分由第一材料形成。
优选地,第一材料为石英石、大理石或花岗石,且面板部件可为由第一材料形成的实心面板的轻质复制品。
在优选的形式中,通过从所述第一材料的材料块中切片出表面片层而形成表面片层。
优选地,通过使材料块行进通过多刀片式切片机,以同时将材料块分成多个相同的切片来形成表面片层,每个切片适合用作面板的表面片层。
优选地,本体层形成为,使得本体层的大部分体积是孔隙空间。
在优选的形式中,本体层由泡沫材料形成。
在一种形式中,表面片层粘附至本体层的一个表面,板粘附至本体层的相对表面。
优选地,侧缘部分的内表面凹陷以容纳表面片层的边缘。
优选的是,面板部件包括由第一材料形成的一对相对的平行侧边缘,平行侧边缘相对于表面片层被固定在位,使得面板部件具有由表面片层和平行侧边缘形成的第一材料的基本恒定的截面,且其中,侧缘部分的凹陷部被构造成,在表面片层和平行侧边缘的边缘处容纳所述截面。
优选地,凹陷部基本为平面的,并位于垂直于表面片层和平行侧边缘的平面内。
优选地,套件包括完成的面板,其中侧缘部分已粘附至面板部件,且分离的侧缘部分是备用的侧缘部分,以便于调整完成了的面板的大小。完成了的面板可在尺寸和/或材料方面根据由客户做出的具体订单来定制。
根据本发明的另一方面,提供有一种形成面板的方法,包括以下步骤:
使用如上所述的套件;
将面板部件切割至适配于暴露面板部件的边缘的尺寸;以及
将侧缘部分粘附至面板部件的所述暴露的边缘。
优选地,粘附侧缘部分的步骤包括将侧缘部分的凹陷部对齐,以盖住表面片层的边缘。
更具体地,粘附侧缘部分的步骤包括将侧缘部分的凹陷部对齐,以盖住表面片层的边缘以及面板部件的平行侧的边缘。
在优选的形式中,切割面板部件的步骤包括以下步骤:横跨面板部件的表面片层和平行侧边缘切割笔直边缘。
在一个示例中,设置有如下面板:该面板包括表面片层和本体层,表面片层由第一材料形成,表面片层粘附至本体层,表面片层大致平行于本体层,其中,本体层的厚度大于表面片层的厚度,本体层的密度小于表面片层的密度,且其中,面板包括沿面板的至少一个边缘粘附的侧缘部分。
优选地,侧缘部分由第一材料形成。
在优选的形式中,第一材料为石英石、大理石或花岗石,且面板为由第一材料形成的实心面板的轻质复制品。
优选地,通过从所述第一材料的材料块中切片出表面片层而形成表面片层。更优选地,通过使材料块行进通过多刀片切片机,以同时将块分成多个相同的切片,从而形成表面片层,每个切片适合用作面板的表面片层。
优选地,本体层形成为,使得本体层的大部分体积是孔隙空间。
优选地,本体层形成有蜂巢结构。更优选地,蜂巢结构的管状元件大致横向于面板的平面延伸。
在一个示例中,本体层由铝形成。替代地,本体层可由泡沫材料形成。泡沫材料可为具有足以抵抗面板的普通使用条件下的受压的强度的聚苯乙烯材料。泡沫材料可为阻燃泡沫材料。
优选地,表面片层粘附至本体层的一个表面,板粘附至本体层的相对表面。
在优选的形式中,表面片层借助胶粘剂粘附至本体层,板借助胶粘剂粘附至本体层。
在一个示例中,侧缘部分围绕面板的整个边缘周界。
在一种形式中,面板是矩形的,且侧缘部分围绕面板的所有四个边缘。
优选地,侧缘部分形成与表面片层的斜接接头。
在另一示例中,提供有一种形成面板的方法,包括以下步骤:
将第一材料块切片,以形成所述第一材料的切片;
使用该切片作为面板的表面片层;
提供本体层,本体层的厚度大于表面片层的厚度,且本体层的密度小于表面片层的密度;
将表面片层粘附至本体层,其中,表面片层和本体层大致平行;以及
沿面板的至少一个边缘粘附侧缘部分。
附图说明
参考附图并借助仅非限制性示例来描述本发明,附图中:
图1示出了根据本发明的示例的形成面板的第一步骤;
图2示出了形成面板的第二步骤;
图3示出了形成面板的第三步骤;
图4示出了形成面板的第四步骤;
图5示出形成面板的第五步骤;
图6示出了完成的面板;以及
图7至18示出了根据本发明的另一示例的用于形成面板的套件的细节。
具体实施方式
参考图1至6,示出有面板10和形成面板10的方法。有利地,面板10包括复合结构,该复合结构使得面板10能够以比作为比较的实心面板更轻的重量形成。此外,在复合面板保持高强度的同时显著减少成本。复合面板可形成为看上去与由相同材料(例如石英石、大理石或花岗石)制成的实心面板相同,使得视觉外观的差异不易被察觉。
更具体地,面板10包括表面片层12和本体层14,表面片层12由第一材料形成,表面片层12粘附至本体层14,且表面片层12大致平行于本体层14。本体层14的厚度大于表面片层12的厚度(如有图4中的相对尺寸所示),且本体层14的密度小于表面片层12的密度。面板10包括侧缘部分16,侧缘部分16沿面板10的至少一个边缘粘附。
本体层14的长度和宽度可稍小于表面片层12的长度和宽度,以容纳围绕面板10各边缘的侧缘部分16。一旦侧缘部分16被粘附至本体层14,完成了的面板10就具有与实心面板相同(或至少大体相似)的外观。例如,在图6中所示的面板10中,第一材料是石英石,且表面片层12和侧缘部分16两者都由该第一材料形成。完成的面板10看上去与实心石英石面板相同,但显著地更轻,成本更高效且作业更安全。
在替代的形式中,第一材料可为大理石或花岗石,使得面板10可分别形成为由大理石或花岗石形成的实心面板的轻质复制品。
通过从第一材料的材料块18中切片出表面片层12而形成表面片层12。在图1中示出了材料块18,切片操作在图2a中所示,且切片后的材料块18在图2b中所示。如图2a中所示,材料块18相对于多刀片切片机通过,以将材料块18同时分成多个相同的切片,每个切片适合用作相应面板10的表面片层12,从而可从单个材料块18中形成多个面板。单个材料块的重量可在20至30吨的等级上。材料块18可由再造石加工而成,以形成石英石块,或在某些情形下,会挖掘到大理石或花岗石。材料块可例如具有以下尺寸:高度1400mm、宽度1200mm、长度3000mm,然而,这些尺寸可根据待形成的面板的尺寸来变化并相配。
图2a示出了具有六个刀片的多刀片切片机20,多刀片切片机20使得由材料块18同时形成六个切片。各刀片间距5mm,使得每个表面片层12的厚度为5mm。图2a以端视图示出了材料块18相对于多刀片切片机20而穿过,图2b示出了被部分地切片的材料块18的立体图。
参考图3,接着,在传送带系统22上,使用多头自动抛光生产线来抛光5mm厚的表面片层12。传送带系统22可具有辊子24,抛光头部26可具有抛光垫,当表面片层12沿传送带系统22被馈送时,抛光垫以90度角度横向于传送带系统22的方向运动。
参考图4,通过压力施加装置28均匀地施加压力,以将面板10的不同部件压缩在一起。更具体地,面板10的不同部件包括表面片层12、本体层14、板30、施加在本体层14与表面片层12之间的胶粘剂32、以及施加在本体层14与板30之间的胶粘剂34。本体层14可形成为,使得本体层14的大部分体积是孔隙空间。这可通过以蜂巢结构来形成本体层14而实现。为了强度目的,蜂巢结构的管状元件可定向为大致横向于面板10的平面而延伸。以此方式,当面板10用作台面时,蜂巢结构的管状元件将竖直地延伸,使得面板具有高的竖直强度。本体层14可由铝形成,然而,在替代的示例中,可使用其它材料。如图4中所示,表面片层12粘附至本体层14的一个表面,板30粘附至本体层14的相对侧。胶粘剂32、34的层可呈环氧粘合剂的形式。在替代的示例中,本体层14可由泡沫材料形成,该泡沫材料可为具有足以抵抗面板10的普通使用条件下的受压的商用强度的聚苯乙烯材料。泡沫材料可为阻燃泡沫材料。可想见,泡沫材料的使用可能对于成本因素、轻量化和/或国家特定的要求是有利的。
参考图5,侧缘部分16被施加至面板10的边缘,且可被施加成围绕面板10的整个周缘。在所示的示例中,面板10是矩形的,且侧缘部分16围绕面板10的所有四个边缘。侧缘部分16和表面片层12以45度斜接,并被胶合在一起,从而形成斜接接头。侧缘部分16的厚度可为5mm,且可从在图2a中所示的切片步骤期间形成的各切片中的一个被切下。
板30可呈铝板的形式。将理解到,虽然在上述详细描述中提到了特定的材料,但在替代的示例中可使用不同的材料。
有利地,由于本体层的厚度大于表面片层12的厚度,且本体层的密度小于表面片层12的密度,故而完成了的面板10比由与表面片层12相同的材料制成的实心面板重量更轻。此外,由于本体层14被表面片层12和侧缘部分16所隐藏,故而面板10的视觉外观与由与表面片层12相同的材料制成的实心面板相同。在某些应用中,板30将不可见;在面板10的基座将为可见的其它示例中,面板10的底表面可被类似于表面片层12的表面片层所覆盖,使得面板10具有由第一材料形成的相对的表面片层12。由此,借助于相对的表面片层12与围绕面板10的全部周界延伸的侧缘部分16一起,在面板10的普通使用期间,本体层14可从外部看来被完全隐藏。
参考图7至18,示出有根据本发明的另一示例的用于形成面板10的套件36的细节。图7至18中所示示例的某些特征与图1至6中所示示例的特征相似,且相同的特征以相同的附图标记示出。
更具体地,在图7至18中示出有用于形成面板10的套件36,套件36包括面板部件38和分离的侧缘部分16。侧缘部分16是凹陷的,使得面板部件38可被切割至期望的尺寸,且凹陷的侧缘部分16能够粘附至面板部件38的在切割操作期间被暴露的侧缘。侧缘部分16的凹陷被布置成盖住由第一材料形成的面板部件38的各部分的切割边缘。
面板部件38包括表面片层12和本体层14,表面片层12由第一材料形成,表面片层12粘附至本体层14,且表面片层12大致平行于本体层14。本体层14的厚度大于表面片层12的厚度,且本体层14的密度小于表面片层12的密度。分离的侧缘部分16适于沿面板部件38的至少一个边缘粘附。
虽然图15示出了具有斜切边缘的本体层14,使得在本体层14与侧边缘44之间存在通道,但在其它示例中,本体层14可直接延伸至侧边缘44而没有倒角或本体层14与侧边缘44之间的任何通道。本体层14的材料可为泡沫材料或不同的轻质材料。本体层14的材料可与面板所模仿的石材的颜色相同。
侧缘部分由第一材料形成。第一材料可为石英石、大理石或花岗石,且面板10可呈由第一材料形成的实心面板的轻质复制品的形式。
本体层14可形成为,使得本体层14的大部分体积是孔隙空间。更具体地,在优选的形式中,本体层14由泡沫材料形成。表面片层12粘附至本体层14的一个表面,板可粘附至本体层14的相对表面。
侧缘部分16的内表面40凹陷,以容纳表面片层12的边缘。面板部件38包括由第一材料形成的一对相对的平行侧边缘44,平行侧边缘相对于表面片层12固定在位,使得面板部件38具有由表面片层12和平行侧边缘44形成的第一材料的基本恒定的截面46。侧缘部分16的凹陷部42构造成容纳表面片层12和平行侧边缘44的边缘处的截面46。
凹陷部42可基本为平面的,并位于垂直于表面片层12和平行侧边缘44的平面内。
形成面板10的方法包括以下步骤:
使用如上所述的套件36;
将面板部件38切割至适配于暴露面板部件38的边缘的尺寸;以及
将侧缘部分16粘附至面板部件38的暴露的边缘。
粘附侧缘部分16的步骤可包括将侧缘部分16的凹陷部42对齐以盖住表面片层12的边缘。更具体地,粘附侧缘部分16的步骤可包括将侧缘部分16的凹陷部42对齐以盖住表面片层12的边缘以及面板部件38的平行侧边缘44。
切割面板部件38的步骤可包括以下步骤:横跨面板部件38的表面片层12和平行侧边缘44切割出笔直边缘。
在替代方式中,分离的侧缘部分16布置成围绕面板部件38的整个周界装配。在矩形面板部件38的情形下,分离的侧缘部分16可布置成围绕面板部件38的所有四个侧边缘装配。套件36可包括已将第一材料的侧缘部分装配至面板部件38的所有侧边缘的面板部件38,使得面板10类似于实心面板,并可附加有备用的侧缘面板16,以备使用者选择调整面板10的大小。在另一形式中,可设置两个备用的凹钝/凹陷侧缘部分,以备使用者想要在两个方向上调整面板10的大小。如果面板10要形成例如厨房中的岛形台面,则面板10的所有四侧边缘必须以所述第一材料完成,使得面板10类似于第一材料的实心面板。否则,如果面板10要安装抵靠墙壁或其它表面,则抵靠墙壁的边缘可不用加盖边缘(或侧缘部分)而完成。
根据本发明的套件允许使用者轻易地调整看上去像大理石(或其它材料)的面板的大小,以适合并可因而被用作可由硬件零售店销售的自助类型的产品,使得人们能够自己装配它们自家的厨房台面等。低密度泡沫材料本体层14便于面板10的切割,从而提供了与由分离的侧缘部分16提供的面板的大小调整之间的特别的作业相互关系。低密度泡沫材料本体层14还便于处于其它原因切割面板10,其它原因例如是切割面板10以适合水盆或其它部件。虽然套件可用作自助的产品,但所完成的面板还可作为定制产品生产,定制产品可能由例如细木工这样的客户所指定。
尽管以上已描述的本发明的各种实施例,但应理解,它们仅作为示例而非作为限制呈现。对相关领域技术人员显而易见的是,可从中做出各种形式上和细节上的变化而不偏离本发明的精神和范围。因而,本发明不应被任何上述示例性实施例所限制。
在本说明书中对任何现有公开物(或从中获得的信息)或任何已知事物的参考不是且不应被当作认可或承认或以任何形式暗示了现有公开物(或从中获得的信息)或已知事物构成本说明书所涉及领域的公知常识的一部分。
在本说明书和以下的权利要求书的全文中,除非上下文做出相反规定的,词语“包括”及其诸如“包含”和“包括了”之类的变形将被理解为表示包括所陈述的完整事物或步骤或完整事物或步骤的组合,但不排除任何其它的完整事物或步骤或完整事物或步骤的组合。

Claims (19)

1.一种用于形成面板的套件,包括面板部件,
所述面板部件包括表面片层和本体层,所述表面片层由第一材料形成,所述表面片层粘附至所述本体层,其中,所述本体层的厚度大于所述表面片层的厚度,所述本体层的密度小于所述表面片层的密度,以及
分离的侧缘部分,所述分离的侧缘部分适于沿所述面板部件的至少一个边缘粘附。
2.根据权利要求1所述的用于形成面板的套件,其特征在于,所述表面片层粘附至所述本体层,使得所述表面片层的中心平面对齐成大致平行于所述本体层的中心平面。
3.根据权利要求1或2所述的用于形成面板的套件,其特征在于,所述侧缘部分包括由所述第一材料形成的部分。
4.根据权利要求1至3中任一项所述的用于形成面板的套件,其特征在于,所述第一材料为石英石、大理石或花岗石,且所述面板部件为由所述第一材料形成的实心面板的轻质复制品。
5.根据权利要求1至4中任一项所述的用于形成面板的套件,其特征在于,通过从所述第一材料的材料块中切片出所述表面片层而形成所述表面片层。
6.根据权利要求5所述的用于形成面板的套件,其特征在于,通过使所述材料块行进通过多刀片切片机,以同时将所述材料块分成多个相同的切片,从而形成所述表面片层,每个切片适合用作面板的表面片层。
7.根据权利要求1至6中任一项所述的用于形成面板的套件,其特征在于,所述本体层形成为,使得所述本体层的大部分体积是孔隙空间。
8.根据权利要求1至7中任一项所述的用于形成面板的套件,其特征在于,所述本体层由泡沫材料形成。
9.根据权利要求1至8中任一项所述的用于形成面板的套件,其特征在于,所述表面片层粘附至所述本体层的一个表面,板粘附至所述本体层的相对表面。
10.根据权利要求1至9中任一项所述的用于形成面板的套件,其特征在于,所述侧缘部分的内表面凹陷,以容纳所述表面片层的边缘。
11.根据权利要求1至10中任一项所述的用于形成面板的套件,其特征在于,所述面板部件包括由所述第一材料形成的一对相对的平行侧边缘,所述平行侧边缘相对于所述表面片层固定在位,使得所述面板部件具有由所述表面片层和平行侧边缘形成的所述第一材料的沿所述面板部件的周界的基本恒定的截面厚度,且其中,所述侧缘部分的凹陷部被构造成,在所述表面片层和所述平行侧边缘的边缘处容纳所述截面厚度。
12.根据权利要求11所述的用于形成面板的套件,其特征在于,所述凹陷部基本为平面的,并位于垂直于所述表面片层和所述平行侧边缘的平面内。
13.根据权利要求1所述的用于形成面板的套件,其特征在于,所述套件包括完成了的面板,其中侧缘部分已粘附至所述面板部件,且所述分离的侧缘部分是备用的侧缘部分,以便于调整所述完成的面板的大小。
14.一种形成面板的方法,包括以下步骤:
使用如权利要求1至13中任一项所限定的套件;
将所述面板部件切割至适配于暴露所述面板部件的边缘的尺寸;以及
将所述侧缘部分粘附至所述面板部件的暴露的所述边缘。
15.根据权利要求14所述的形成面板的方法,其特征在于,粘附所述侧缘部分的步骤包括将所述侧缘部分的凹陷部对齐,以盖住所述表面片层的边缘。
16.根据权利要求15所述的形成面板的方法,其特征在于,粘附所述侧缘部分的步骤包括将所述侧缘部分的所述凹陷部对齐,以盖住所述表面片层的所述边缘和所述面板部件的平行侧边缘。
17.根据权利要求14至16中任一项所述的形成面板的方法,其特征在于,切割所述面板部件的步骤包括以下步骤:横跨所述面板部件的所述表面片层和平行侧边缘切割出笔直边缘。
18.一种基本如此前参考附图描述的面板。
19.一种基本如此前参考附图描述的形成面板的方法。
CN201580053797.4A 2014-08-04 2015-08-04 用于形成面板的套件以及形成面板的方法 Pending CN107107538A (zh)

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