DE102005033325A1 - Production process for thin stone slabs involves sawing slabs glued to support using splitting machine - Google Patents

Abstract

The production process involves sawing thin stone slabs (1) on a carrier from thicker stone slabs with a support (2) glued to both sides. The thicker stone slabs with the support on both sides are sawn into thin ones with the aid of a splitting machine (4) with several diamond-tipped saw blades of increasing diameter one behind the other.

Description

The The invention relates to a new process for the production of natural stone slabs with a thickness between 1 and 6 mm fixed on a support.

Basically thin natural stone slabs that on a carrier glued on are already known. They are made by making thicker ones Natural stone slabs, which are fixed on a carrier, material-consuming and costly with a router be calibrated down. In other cases, thicker natural stone slabs both sides each with a carrier glued and then sawn through in the middle with a rope or gang saw. The Here are obtained cut surfaces uneven and must be recalibrated accordingly consuming. These procedures are time-consuming and costly, so that a continuous industrial production not possible is. In the case of soft marble are so-called horizontally working Splitting machines with two rows arranged parallel to each other consisting of 2 to 3 successive circular saws in the trade, to thicker marble slabs to marble slabs with a thickness of 1 to split to 1.5 cm.

To the Columns of the much harder Granits are not usable on these machines.

• a.: die Haftung zwischen den Natursteinplatten und den Trägerplatten durch die unvermeidbar intensive Einwirkung von Schlemm- und Kühlwasser den Kleber zerstörend angreifen würde.
• b.: unter der hohen mechanischen Belastung bei Schnittdicken unter 0,6 cm das Auftreten von Rissbildungen im Naturstein unvermeidlich ist.
• c.: sich bereits einige Zeit nach der Verklebung der Natursteine auf einen Träger (insbesondere bei Trägern mit einer Stärke unter 2 cm auf Basis Holz, Recyclingstoffe oder Kunststoff) das Plattensystem mehr oder weniger stark verbiegt.

For granite a sawing machine is known, which was produced only in small numbers. This machine operates several diamonds with saw blades and rising sawblade diameter (drawing 1). Granite tiles with a thickness of not less than 0.6 cm can be produced with this machine. In the production of 0.6 cm thick plates, the loss due to plate fracture is unacceptably high because of the high mechanical stress. The use of fixed on carriers natural stone slabs of marble, granite or slate did not take place, as was foreseeable for the expert that

• a .: the adhesion between the natural stone slabs and the support plates by the unavoidably intense action of Schlemm and cooling water would attack the adhesive destroying.
• For example, under the high mechanical load at cut thicknesses below 0.6 cm, the occurrence of cracking in natural stone is unavoidable.
• c .: already some time after the bonding of natural stones on a support (especially for straps with a thickness of less than 2 cm based on wood, recycled materials or plastic) bends the plate system more or less strong.

So it is also understandable that thin-stone plates with a thickness below 0.6 cm fixed on a support for a wide commercial use e.g. not offered in the construction sector (floors, walls or facades) because of the mass production processes described above are too expensive.

Surprisingly, it has now been found that, with the abovementioned type of sawing machines, intact natural stone slabs of a thickness of less than 6 mm can be produced fixed on a support, if the natural stones have a largely water-resistant and elastic type of adhesive based on silicone, polyurethane or epoxy (one- or two-component adhesive) can be fixed to the respective carrier. Of course, the thickness of sawn natural stone can also be selected in the range greater than 6 mm. It was found that the systems of natural stones on supports were particularly resistant to detachment processes, bending or cracking when the natural stone is provided with a thin glass fiber or plastic layer before being fixed to a support. Here, the fiber is also applied with the elastic epoxy or PU adhesive. It is noteworthy that 1500 m ² / day of granite / carrier plates can be produced easily with one machine. The cut is completely flat after appropriate machine adjustment, so that hardly needs to be recalibrated. Due to this method, plate systems made in this way can be widely used. Material loss is minimized and natural resources are spared accordingly.

The sawing machine consists as mentioned above of a series (drawing 1) connected in series Saw blades (diamond occupied) rising saw blade diameter. In series can arranged more than 20 saw blades be. Each saw blade saws each one piece deeper into the stone For example, in granite by the 1st sawblade 15 to 20 mm deep cut, the next blade leaves more 15 to 20 mm deep, etc.

The Saw blades can be horizontal or be arranged at an inclination angle. The water supply to the Cool and for slurrying of the sawdust is going through the arrangement of the saw blades guaranteed.

Around wider plates of thin stone on support plates make a machine type that consists of two parallel, However, staggered rows of blades consists. each blade row consists of several diamonds in a row Soaring saw blades Blade diameter (drawing 1).

The stone is sawn on both sides at the same time. (Drawing 2).

in the Case of single-row sawing machines can a doubling of the plate width can be achieved by first the Stone cut through half, and then turned off from the other side in the second saw.

The achievable width of Dunnsteinplatten is technically limited by the diameter of the saw blades, the another vibration-free sawing process allowed. The on special carriers applied natural stone layers with a thickness of 1 mm to 6 mm are economically extremely interesting because in relation to achieved a significant weight reduction for massive natural stone which results in a broad spectrum of applications, i.a. in the fields: Construction (floors, walls, ceilings, Facades, roofs), Furniture, Kitchen countertops, Aviation, caravans, yachts or railway construction opens up.

For example as 3 mm thick granite layer glued on cold or heat insulating lightweight construction such expanded glass or plastic honeycomb panels can be completely new "roof tiles" made of exquisite granite produce.

One Another advantage is that plates made of porous or friable Natural stone types, which until now only for reasons of stability in thicknesses over 2 cm can be produced and used are over now a thin one Glass fiber layer on a support fixed on strengths under 10 mm can be used without problems.

At the Use of support materials such as. HDF, or recycled materials can be used in private areas and floors Walls essential easier to lay with natural stones than if heavyweight massive natural stone slabs must be laid. If the carrier with a tongue / groove system or a click system is equipped, The layman will also be able to do it your self-procedure the thin stone plates to lay, especially since the cutting of the thin stone slabs with simple cutting equipment the hardware stores possible is. Even a dry laying can be done without manual skill done by the layman When thin tubes of e.g. copper are inserted into the carrier, receives one natural stone modules with integrated floor heating.

The present invention claims thin natural stone slabs adhered to support materials with a thickness of natural stone of 1 mm to 6 mm, prepared according to the following in a continuous process carried out method:
A natural stone block, which is glued to a support, is sawed off at a desired distance from the support (eg 2 mm) with the sawing machine described.
The achievable width of Dunnsteinplatten is technically limited by the diameter of the saw blades, which still allows a vibration-free sawing. The progressive development in the sector of natural stone saw blades using new alloys currently allows the production of thin stone slabs with a width of more than 60 cm.

Corresponding The present invention is a natural stone block before the sawing process calculated thickness optionally after application of a glass or plastic fiber fixed with an elastic highly water-resistant adhesive on the respective carrier. The thickness of the Natusteinblockes corresponds to the desired Number thin layered Natural stone slabs under consideration the saw loss. After sawing a thin one Natural stone layer (for example 2 mm layer thickness) fixed on a support the remaining natural stone block again as described above a carrier glued. Again a e.g. 2 mm thick layer together with the new carrier sawed off, without an adjustment and adjustment of the saw blades is required. Of the The process repeats until the stone block reaches a thickness of About 10 mm is removed.

In As a rule, the stone block has a thickness of 0.8 cm to 20 cm, preferably 1 cm to 8 cm.

To sawing are fixed on the carrier thin stones automatically singled out and over roller conveyors in a conventional Production line for calibration, polishing and chamfering.

• – die ca. 10 mm Steinrestplatten können ohne Träger in den Kalibrier- und Polierprozeß eingeschleust werden und zu herkömmlichen Fliesen verarbeitet werden.
• – die ca. 10 mm Steinrestplatten können auf einer Seite mit dem Ursprungsträger und auf der anderen Seite mit einem anderen Träger verklebt werden und dann bei gleicher Maschineneinstellung zersägt werden Man erhält so zwei Dünnsteinplatten jeweils fixiert auf einen anderen Träger. Dies ist dann von wirtschaftlicher Bedeutung, wenn an einem Trägersystem ein nur geringer Bedarf besteht. (beispielsweise wird ein Steinblock bis zu der 10 mm Reststeinplatte jeweils auf einem HDF- Träger für den Baubereich verklebt. Der Reststein von ca. 10 mm wird dann auf der Unterseite mit dem HDF-Träger und auf der Oberseite mit einem Leichtbauträger für die Auskleidung von Schiffen oder Flugzeugen o.ä. beklebt.)
• – die ca. 10 mm Steinrestplatten werden beidseits mit dem Ausgangsträger verklebt und dann bei gleicher Maschineneinstellung zersägt, wobei die obere Hälfte nach dem Zersägen nachkalibriert werden muss. Auf diese Art wird der gesamte Natursteinblock in Dünnsteinplatten mit gleicher Trägerart aufgesägt.

The remaining block of stone is automatically redirected to the gluing and sawing process via conveyor belts. If the stone has been removed to a thickness of approx. 10 mm, different methods can be used, depending on the economic requirements:

• - The approximately 10 mm stone remnants can be introduced without carriers in the calibration and polishing process and processed into conventional tiles.
• - The approximately 10 mm stone remnants can be glued on one side with the origin carrier and on the other side with another carrier and then sawn at the same machine setting you get so two thin stone plates each fixed to another carrier. This is of economic importance if there is only a small need for a carrier system. (For example, a block of stone up to the 10 mm remaining stone slab is glued on a HDF support for the construction sector.) The residual stone of approx. 10 mm is then placed on the underside with the HDF support and on the top with a lightweight support for the lining of Ships or aircraft or similar.)
• - The approximately 10 mm stone remnants are on both sides glued to the output carrier and then sawn at the same machine setting, the upper half must be recalibrated after sawing. In this way, the entire block of natural stone is sawn in thin slabs with the same type of carrier.

Of course you can too from the beginning about 1 cm thick natural stone slabs on both sides with the same carrier material be pasted and then sawn through in the middle.

Becomes a block of natural stone with less adhesive adhesives on one simple carrier e.g. Glued on wood, after splitting the obtained Plate of thin stone and carriers on the stone side with an elastic PU or epoxy adhesive on another carrier glued firmly together with other stone slabs. The first carrier can by a special method e.g. by treatment with hot water superseded become. The with the elastic glue and if necessary over a Fiberglass net firmly glued second carrier plate does not dissolve in this case. To followed by Calibration and polishing obtained you get a big, exclusive natural stone surface, the cut surfaces when considering the grain of the individual natural stone slabs hardly are visible.

Becomes an extremely thin one Natural stone layer (z.B .: 0.5 to 1 mm) desired on carrier, can with refrain from a significant pressure on polishing, if after sawing the raw stone surface with a special 2-component varnish of diisocyanate, for example toluene-2,4-diisocyanate or isophorone diisocyanate or hexyl diisocyanate and a dialcohol For example: Butanediol overcoated becomes. The stone surface now has a shine that does not match that of a polished surface to distinguish. At the same time you get a seal of Natural stone surface especially for a marble occupancy in baths or kitchens is advantageous.

With This paint system can be used for the interior basically a raw, unpolished natural stone surface, whether on a support or massively brought to shine.

For a dry installation or a self-sacrifice in the do it your self procedure can be with the carrier a tongue and groove system or with a click or lock milling provided The gap between 2 panels can be closed by that the plate edges are covered with a plastic or rubber strip which provide a good seal against moisture. Extension number corresponding colorations and thickness e.g. in the case of a PVC strip can when folding the plates are formed an automatic joint. Of course you can after laying the plates, the joint also conventionally with be closed with an elastic joint adhesive.

in the Trap of water impermeable carriers can the carriers before sticking with holes be provided by after the laying of the thin stone slabs the moisture or the solvent of the laying adhesive over can escape the natural stone.

The according to the patent application for use coming natural stones are all kinds of granite and marble and slate. to increase the flexibility and stability can The natural stones should be pasted with a fiberglass or carbon fiber fabric.

Suitable carriers are, for example:
HDF boards, MDF boards, screen printing plates,
Carriers made of recycled material eg: Phonotherm plates,
Support made of hard foam or of compact plastic, for example: polyacrylic, HPS (polystyrene), polycarbonate, polyester, polyetherimide, polypropylene, polyethylene, polyamide
Carrier made of honeycomb plastic (eg Honeycomb systems): polyacrylic, polystyrene, polypropylene, polyethylene, polyester, polyetherimide, polyamide, aramid, wherein the interior of the plastics each have a honeycomb structure
having.

Carrier off Light metals such as aluminum or titanium. Between two metal plates can honeycomb-like plastic inserts e.g. made of: polyacrylic, polystyrene, Polyamide, polypropylene, polyethylene, polyetherimide, polyamide, aramid are located.

Carrier made of glass foam, expanded glass, aerated concrete, Glass

Carrier off cheap natural stones (for example: in a thickness of 1 cm) can be used be so high quality natural stone made of marble or granite very thinly cut (For example, in a thickness of 2 mm) can be used virtually massive. The advantage here lies in the saving of valuable natural stone.

• – einem Melamin- oder Phenolharz
• – einer Kohlefaser oder Glasfaser

In some cases (for example with hard foam or HDF supports), it may be advantageous to coat the supports used in the process from the top and bottom
eg with

• A melamine or phenolic resin
• - a carbon fiber or glass fiber

1. Production of plates consisting of 3 mm thick marble slabs glued to 8 mm thick HDF carriers.

One 58 mm thick block of Estremoz marble with dimensions: 61 cm long and 30.5 cm wide by means of an elastic PU adhesive with a thin one Fiberglass and then with the same adhesive to an 8 mm thick, 61 cm long and 30.5 cm wide HDF plate glued. The HDF material is multi-layered with water impermeable films fitted.

In addition is the carrier plate coated on the top and bottom with a plastic layer.

With a sawing machine the marble block becomes 3 mm from the carrier sawn away. The machine consists of two parallel rows from each 3 saw blades. The each offset lying leaves have the same diameter. Within the ranks of the rises Saw blade diameter at. The saw blades are Diamond occupied.

you receives now the carrier plate with a 3 mm thick marble layer. The remaining marble block now has only a thickness of 52 mm (3 mm are lost in the form of sawdust).

As described above is glued again a carrier and another Removed marble layer, etc. So you get 8 sheets of 3 mm thick marble on 8 mm thick HDF carriers. These plates have a length of 61 cm and a width of 30.5 cm.

It Remains a natural stone remnant plate of 10 mm.

The 8 slabs of marble glued on a HDF carrier and the 10 mm solid Marble slab is calibrated, chastised and polished.

2. Production of plates consisting of 3 mm thick marble slabs glued on 8 mm thick HDF straps and a slab made of a 30 mm thick lightweight carrier with a 2 mm thick marble layer.

One 56 mm thick block of Estremoz marble with the dimensions: 61 cm long and 30.5 cm wide is described as in Example 1 glued to an 8 mm thick, 61 cm long and 0.5 cm wide HDF board. The carrier plate is plastic coated on the top and bottom.

With a sawing machine the marble block becomes 3 mm from the carrier sawn away. The machine consists of two parallel rows from each 3 saw blades. The each offset lying leaves have the same diameter. Within the ranks of the rises Saw blade diameter. The saw blades are Diamond occupied.

you receives now the carrier plate with a 3 mm thick marble layer.

Of the remained marble block has now only a thickness of 50 mm (3 mm go in the form of sawdust lost).

As described above is glued again a carrier and another Removed marble layer, etc. So you get 7 plates of 3 mm thick marble on 8 mm thick HDF carriers. These plates have a length of 61 cm and a width of 30.5 cm. There remains a natural stone slab of 14 mm. This plate is covered on the bottom with the HDF carrier and stuck on top with a 30 mm thick lightweight carrier. Again, with the same machine setting HDF plate with sawn off a 3 mm thick marble layer. There remains a plate consisting of the lightweight carrier and an 8 mm thick marble layer. This plate will turn with the HDF carrier stuck and with the same machine setting is again a plate made of HDF carrier and sawed off a 3 mm thick marble layer. There remains a plate consisting of the lightweight carrier fixed on a 2 mm thick marble layer.

The obtained slabs of natural stone on support are calibrated, bevelled and polished.

The with a 2 mm thick layer of marble glued lightweight board is calibrated and polished separately.

3. Production of plates consisting of 3 mm thick granite slabs glued to 8 mm thick HDF carriers. It remains as desired a 10 mm strong massive granite tile.

One 58 mm thick block of Blue Pearl granite with dimensions: 61 cm long and 30.5 cm wide by means of an elastic PU adhesive with a thin one Fiberglass and then with the same adhesive to an 8 mm thick, 61 cm long and 30.5 cm wide HDF plate glued. The support plate is plastic coated on the top and bottom.

With a sawing machine the granite block becomes 3 mm from the carrier sawn away. This machine consists of a series of 12 consecutive-switched Soaring saw blades Saw blade diameter. The saw blades are Diamond occupied. You get now the carrier plate with a 3 mm thick granite layer.

Of the remaining granite block now has a thickness of 52 mm (3 mm go in the form of sawdust lost). As described above, a carrier is glued again and another granite layer is removed, etc., thus obtaining 8 Sheets of 3 mm thick granite on 8 mm thick HDF carriers. These plates have a length of 61 cm and a width of 30.5 cm. There remains a natural stone slab of 10 mm, which is calibrated, polished and chamfered separately.

The 8 granite slabs glued to an HDF support are also calibrated chastised and polished.

4. Production of plates consisting of 3 mm thick granite slabs glued on 30 mm thick carrier plates made of glass foam.

One 46 mm thick block of Blue Pearl granite with the dimensions: 62 cm wide and 200 cm long by means of an elastic epoxy adhesive with a thin one Fiberglass and then with the same glue on a same size but 30 mm thick carrier plate glued from glass foam.

With a sawing machine the granite block becomes 3 mm from the carrier cut away horizontally. This machine consists of a series of 20 consecutively-connected Soaring saw blades Saw blade diameter. The saw blades are Diamond occupied. The half-sawn block becomes from the opposite side Her with a second similar machine with the same saw blade adjustment completely cut.

you receives now as in the previous examples described a 62 cm wide and 200 cm long support plate covered with a 3 mm thick granite layer. The remaining granite block now has a thickness of 40 mm (3 mm are lost in the form of sawdust). As described above, a carrier is glued again and another Granite layer removed, etc. This gives 6 plates of 3 mm thick Granite on 30 mm thick glass foam carriers. These plates have one length of 200 cm and a width of 62 cm.

It remains a natural stone plate of 10 mm, the both sides with the Glass foam carrier is glued and then separated at the same machine setting becomes.

you receives thus 8 glass foam plates of dimensions 62 cm × 200 cm with a thickness of 30 mm covered with a 3 mm thick layer of Blue Pearl. The plates are calibrated and polished.

6. varnishing of raw, dull natural stone surfaces

The according to Example 2 obtained directly after the sawing lightweight board with a 2 mm thick marble layer (with still blunt stone surface) becomes after a special drying process with a 2-component paint treated. The paint consists of an aromatic diisocyanate and an aliphatic dialcohol and is mixed in an organic thinner on the dull stone surface atomized. After curing receives a shiny one Surface, extending from a polished surface can not distinguish.

Claims (9)

Requested are plate systems made of thin natural stone layers fixed on various carrier materials, which thereby be prepared that natural stone slabs with a thickness of 0.8 cm to 20 cm with a suitable adhesive on a support or between two carriers be fixed, and then with a special sawing machine in a predetermined Distance to the lower beam be sawn through. Natural stone support plates according to claim 1, that the adhered to a support natural stone slabs can be separated up to a layer thickness of 1 mm Natural stone support plates according to claim 1 to 2, that the glued natural stone plates Marble, granite or slate exist and on the bottom with a glass fiber or carbon fiber fabric may be coated. Natural stone support plates according to the claims 1 to 3, that thin Natural stone layers on carrier Made by a natural stone block on the bottom and optionally on top with the same or one various carriers is glued and with the help of a sawing machine in an adjustable sawn parallel distance to the lower beam, the machine with more than 20 connected in series, Rising with diamond-covered saw blades Size is equipped and the sawing process after re-gluing the remaining natural stone block with a carrier is repeated until the original block is worn away. Natural stone support plates according to the claims 1 to 4, that the carrier 5 mm to 100 mm, preferably 7 mm to 30 mm thick. Natural stone carrier plates according to claims 1 to 5, that the carrier based on wood, plastic, metal, natural stone, mineral, glass or Re cycling material can be constructed. Natural stone support plates according to the claims 1 to 6 that the wearer may be coated on the top and bottom, e.g. With - one Melamine or phenolic resin - one Carbon fiber or glass fiber Natural stone support plates according to the claims 1 to 7 that blunt after a sawing process accumulating natural stone surfaces instead of a mechanical polishing with a 2-component paint made to shine on the basis of polyurethane can be. Natural stone support plates according to the claims 1 to 7, that the thin stone plates granite on support when covering roofs can be used.