DE102019120406A1 - Plate body - Google Patents

Abstract

The invention relates to a plate body with a multi-layer structure, a first upper layer (4), which in use forms an outer surface, consists of a ceramic material, natural stone or a quartz composite presenting a stone-like work surface, a second layer (5), which under the The first layer (4) consists of a mineral granulate bonded to form a body by means of a binder, and a third layer (6) which is arranged below the second layer (5). In order to specify a panel body which, while being industrially producible, meets the practical requirements of such a panel body as best as possible, it is proposed that the first layer (4) change in volume directly by means of a binder different from the binding agent of the second layer (5) in the course of curing enlarging adhesive (7) is connected, wherein the adhesive (7) is present closely encompassing a three-dimensional surface structure of the second layer (5).

Description

Field of technology

The invention relates to a plate body with a multi-layer structure, a first layer, which in use forms an outer surface, consists of a ceramic material, natural stone, a quartz composite or some other stone-like material that presents a stone-like outer surface, a second layer, which is below the first Layer is arranged, consists of a mineral granulate joined to form a body by means of a binder and a third layer, which is arranged below the second layer.

The invention further relates to a method for producing a plate body with a multilayer structure, a first layer, which in use forms an outer surface, consists of a natural stone presenting a stone-like outer surface, a ceramic material, a quartz composite or some other stone-like material, a second Layer, which is arranged below the first layer, consists of a mineral granulate joined to form a body by means of a binder, and a third layer, which is arranged below the second layer.

State of the art

Such plate bodies and their production are already known in various respects. Among other things, as also preferred in the context of the registration, if necessary with corresponding further adaptation, as worktops for kitchens. In this case, the first layer forms an upper layer, which represents the work surface. Such worktops are already known from a natural stone forming the upper outer surface.

In a known worktop in which the upper layer forming an outer surface is made of natural stone, the connection to the further layer consisting of expanded glass granulate is achieved by means of a support material layer made of carbon fiber laminate, the carbon fibers being mixed with resin.

For the state of the art, refer to the DE 195 19 116 A1 to refer. In the case of the natural stone lightweight construction panel known from this, an adhesive film is applied to a lightweight carrier panel and the natural stone panel is connected to the lightweight carrier panel by means of this adhesive film at temperature and pressure.

From the DE 10 2011 108 996 B3 a two-layer composite panel is known in which a natural stone panel is connected to a mixture of broken and ground stone by means of an adhesive. An epoxy resin is used as the adhesive, which is subject to shrinkage as it cures. From the DE 10 2010 034 851 B4 a method for producing a composite panel is known, wherein a mixture of crushed and crushed rock is sprinkled on a surface of the natural stone panel provided with adhesive and a second adhesive is applied to the rock material after the first adhesive has hardened. An epoxy resin, which is subject to shrinkage as it cures, is used as the first and second adhesive. Next is on that DE 10 2010 003 236 U1 to refer, from which it is known to form a mineral cast layer of quartz sand, quartz powder and epoxy resin as a binder between a base layer made of a foam glass granulate mixture with epoxy resin as the binder, with a material bond with the base layer.

From the EP 1 153 738 A1 a plate body is known which is produced on the basis of a natural stone plate provided on both sides with a stabilizing layer as part of a carrier layer, the stabilizing layer being a mineral fiber mat embedded in resin. At a respective distance from the stabilization layer, a further stabilization layer is arranged on both sides and the free space thus created is formed as a respective intermediate layer from a rigid foam. In further detail, the free spaces are first filled with granules with a grain size between 3 and 6 mm and then foamed, after which the natural stone slab is divided along its central plane.

The known plate bodies are comparatively expensive to manufacture or do not always prove to be reliable with regard to the requirements that are placed on such a plate body. An adhesive film is particularly difficult to handle and in practice it may not be able to meet the requirements that are to be made of a panel body that can basically be used worldwide in every respect. The attachment between the known locations is not always satisfactory.

With regard to the requirements placed on such a panel body, the requirements up to the installation of the panel body are often more important than the requirements that have to be met in the actual installation state. In particular, these are requirements that can arise during transport or storage, for example with regard to bending moments, vibrations and temperature stress. The panel body must meet all of these requirements, including those in daily use after installation requirements with regard to weather resistance, cut resistance and / or cleanability etc. At the same time, however, the plate body should also have the lowest possible weight. In addition, the plate body should be easy to process, for which in particular screwability and / or cut-to-size (in particular by sawing) is required. Last but not least, it should be producible at a competitive price.

With regard to an outer surface made of another stone-like material, it can be, for example, a material that consists of a plastic / granulate mixture. Ultimately, any other stone-like material refers to any material that offers a user a surface with a stone-like quality.

Summary of the invention

Based on the prior art presented, the invention is concerned with the task of specifying a panel body which, while being industrially producible, meets the practical requirements of such a panel body in the best possible way, in particular for ultimate use as a worktop in a kitchen. In addition, the invention is also concerned with the task of specifying a relevant manufacturing method.

With regard to the panel body, this object is achieved first and foremost in the subject matter of claim 1, the aim being that the first layer is directly connected to the second layer by means of an adhesive that increases in volume in the course of curing, the adhesive being a three-dimensional one The surface structure of the second layer is closely encompassing and is different from the binder of the second layer or also forms the binder of the second layer, and / or that more than 50% of the granules are spherical granules and the spherical granules are present in fractions with different diameters, wherein a fraction with a proportion of 10% or more, up to, for example, 90% of the granulate, has a diameter of 1 mm or less, the first layer furthermore being connected to the second layer by means of an adhesive which increases in volume during the course of curing is connected, the adhesive being a three-dimensional nal surface structure of the second layer is present closely and is different from the binder of the second layer or also forms the binder of the second layer.

The volume-increasing adhesive is advantageous with regard to the desired firm connection between the first and the second layer. One can also speak of a clawing adhesive. It is preferably a one-component adhesive. A suitably high setting of the viscosity can support this clawing property. On the other hand, although the setting of the viscosity is not primarily important, it can also be a two-component adhesive. The increasing volume can be achieved independently of a one- or two-component adhesive in that the adhesive is a foaming adhesive.

The fact that there is a direct connection between the first layer and the second layer in the course of curing of the adhesive increasing in volume, on the one hand, a very intimate connection between the first layer and the second layer is achieved. At the same time, however, a very rational production method can also be implemented, since the first layer does not require any supplementation, for example, by a carrier layer or stabilizing layer. Nevertheless, such a carrier layer can optionally also be provided, see further below.

Such plate bodies are to be viewed in particular as semi-finished products for the further processing and manufacture of, for example, worktops, as are mainly common in kitchens. In addition, it can also be, for example, a facade panel, an interior fitting panel, a window sill, a door, both exterior and interior doors relating to a building, or the like, to which such a semi-finished product is ultimately processed. In further detail, this can also be, for example, a plate part in a bathroom or a wet cell area in general. With regard to industrial producibility, it is essential that the plate bodies are manufactured as large components with the largest possible dimensions, for example as rectangular bodies with a width of 1.3 m to 2.1 m or more and a length of 2.5 m to 4 m or longer. A currently preferred greatest length is 3.65 m. Industrial production also means that the respective layers are formed over the entire surface and practically homogeneously throughout in the respective volume. Thus, they also serve as starting plate bodies for applications in which certain areas of a layer do not necessarily have to be present over the entire area but are then given over the entire area due to the use of these plate bodies.

With regard to a worktop for kitchens, starting from the semi-finished product, cutting to size is required and, as a rule, edges are glued. Before this, especially in the case of natural stone, it is preferred to carry out a surface treatment, at least on the visible side. For example by grinding and / or polishing. In addition, to complete a Kitchen furniture with such a worktop a screw and / or adhesive connection can be made with a piece of furniture.

The edge gluing can be done with a stone edge or an edge made of another material. In particular, gluing with a plastic edge, in this case preferably a plastic edge made of PP, is also possible and currently preferred.

When used, for example, as a door, it is advisable to also carry out the surface treatment mentioned. Appropriately, but not necessarily, the surface treatment is then carried out on both opposite outer sides, which are each a visible side.

The connection of the first layer to the second layer directly by means of an adhesive that increases in volume in the course of curing produces a desired and reliable connection between the first and second layers that takes up only a small amount of space. A separate layer apart from the adhesive is basically not required, but it can nonetheless be provided that an additional layer, in particular a fabric layer, in particular adhering to the first layer, is provided. Due to the particularly three-dimensional structure of the surface of the second layer, despite the adhesive and possibly also the further layer, there can be a direct contact - or limited area-wise overlapping - between the first and the second layer. Due to the three-dimensional structure, the first layer can be supported directly on the second layer in a point-like or patch-like manner in many places. The same naturally also applies in the event that the mentioned additional layer, in particular a fabric layer, is provided on the side of the first layer. The adhesive itself can also be applied amorphously, for example as a liquid adhesive. The adhesive is given a favorable free expandability, which enables a close encompassing of the three-dimensional surface structure of the second layer, and thereby, as it were, a clamping, or at least a filling of the spaces given by a mere contact with the underside of the first layer.

The binding agent of the second layer can be selected to match the adhesive between the first and second layers as an adhesive increasing in volume, in particular a PU adhesive. In this case, if the second layer is applied to the first layer "wet", i.e. when the adhesive is still liquid, a separate adhesive layer between the first and the second layer can be dispensed with, which then rather forms in the course of curing, as explained further below, preferably under pressure, and the associated increase in volume of the adhesive, which here also forms the binder of the second layer.

According to a preferred embodiment, the second layer is provided as an initially separately manufactured plate body, also in the possible variant with the adhesive increasing in volume as the binding agent, and then the separate adhesive layer is still applied between the first and second layer.

With regard to a manufacturing method for such a plate body, the object is initially and essentially achieved in that an adhesive that increases in volume during the course of curing is applied to a rear side of the first layer and then a granulate layer, possibly as a previously completed independent plate body, is applied, which has a binder, which can also be given by the adhesive, which increases in volume, or is different from the adhesive, and that the granular layer is connected to the first layer under the action of pressure.

This production method produces the already described favorable, close encompassing of a three-dimensional surface structure, at least the second layer.

The production immediately produces a final design of the panel body with regard to a layer structure. This does not contradict the fact that separations are made perpendicular to the surface extension and / or the edges are machined or other surface machining is carried out. In particular, however, following the production described, no further engagement is made on the first layer in the sense of a division, for example by sawing, in a surface direction of the first layer. Rather, the first layer essentially already forms, with the possible exception of a surface treatment, the final and final usable surface of the panel body.

The surface structure of the second layer is preferably significantly more uneven than the assigned surface structure of the first layer, that is to say forming an underside of the first layer, and is optionally jagged compared to the facing surface of the first layer. The degree of a surface roughness of the surface structure of the second layer, also known as the roughness value, is preferably above RZ 25 (mean roughness depth in μm), which can be determined using the stylus method, for example. The underside of the first layer can, however, also have a distinct unevenness, in this case up to one same or even greater unevenness than the facing surface of the second layer.

With regard to a finished panel body, possibly in the use of a worktop, the said roughness can also be determined by making a severing cut perpendicular to a surface extension of the panel body and recording the line structure resulting at the transition from the adhesive layer to the second layer and the deviations compared to a median plane resulting therein, which is to be specified extending parallel to the surface extension mentioned, can be determined as deviation dimensions with regard to the surface roughness mentioned. In absolute terms, it is certainly preferable that variations from the center plane in the range of _^1/10 mm or more to 1 mm or even result beyond.

With regard to a total thickness of such a plate body, it is preferred that this is in the range from 10 mm to 50 mm. Here, the first layer can have a thickness dimension of 1 mm to 10 mm, preferably in the range of 2 mm to 6 mm, and the third layer, as explained further below, preferably be formed comparatively thin, in the range of 1 mm. The difference dimension for the second layer results accordingly. This in particular also with regard to a common thickness dimension for a worktop in a kitchen, which is 38 mm. However, thicknesses which differ from this can also be used in a sensible manner.

A panel body, and optionally a worktop based on it, with one or more of the features as explained above and below, can in particular also be advantageously screw-connected to a further part, such as for example a piece of furniture. The screw connection can in particular be made from below, through the third layer, into the second layer.

The second layer, which consists of the mineral granules, is preferably formed on the basis of spherical mineral granules. In any case, it is preferred and desired that a substantial proportion, approx. 50% or more of the granules, are spherical granules. These spherical granules are in a closed or essentially closed form. It is further preferred that there is a mixture of granular bodies of different sizes, thus possibly also a mixture of spherical and non-spherical granular bodies. With regard to the preferred spherical shape, this can relate to a bandwidth of approximately 0.01 mm to approximately 4.0 mm in diameter. Here, preferably three to six, more preferably four or five, different fractions are formed, which can accordingly have an average of 4 mm, 3 mm, 2 mm, 1 mm, 0.1 mm and 0.01 mm in diameter, with regard to the mean intermediate sizes such as 2.5 mm, 3.5 mm, 1.5 mm, 0.15 mm and / or 0.015 can also be provided. On the other hand, the fractions can also be described to the effect that they contain granules with a size of 2.0 mm to 4.0 mm, from 1.0 mm to 2 mm, from 0.5 mm to 1 mm, from 0.2 mm to 0.5 mm, from 0.1 mm to 0.3 mm and from 0.01 mm to 0.03 mm. Such fractions are preferably mixed to form the granulate in such a proportion that each fraction ultimately comprises approximately the same volume based on the granulate mixture obtained.

Other non-spherical granules can also be used partially or entirely. This non-spherical granulate preferably has a maximum dimension in a plan view, likewise in a range of 0.01 mm to 4 mm. Here, too, different, preferably four to six, more preferably five different fractions can be formed, which on average can have a maximum size of 4 mm, 3 mm, 2 mm, 1 mm, 0.1 mm and 0.01 mm, whereby intermediate sizes such as 2, 5 mm or 3 mm in the largest dimension can also be provided.

The mineral granules can in particular be expanded glass granules. But it can also be, for example, expanded sand, which is also known under the name tobermorite.

The granulate bodies are connected to one another by a binding agent which is preferably provided for this purpose. It can be a resin. It can also be a two-component resin. The two-component resin can be an epoxy resin. The binder for the granules can also be a PU (polyurethane) adhesive. A PU adhesive that does not expand when it cures is preferably used here. As indicated, however, the binder can alternatively also be an adhesive that increases in volume on curing, in particular also a PU adhesive.

During processing, the granular bodies can already be present as a sheet that can be handled by itself, correspondingly with a binder matrix. This body, as a layer of the plate body, can, however, also only be formed in the course of a layer formation, by sprinkling or pouring on granulate bodies interspersed with binding agent.

Here, ie during the production and also with regard to the finished granulate body, the proportion of the binder is also essential. In terms of volume, the proportion of binder in a liquid phase is preferably between 2% and 15% of the volume of the granulate bodies total without binder. More preferably between 10% and 6%. More preferably between 7% and 8%, for example 7.5% by volume.

The fact that the adhesive, which increases in volume and / or has the property of clawing, is preferably different from the binder in the second layer, which consists of the mineral granulate, can have a beneficial effect on the cohesion between the layers by means of this during curing Volume-increasing adhesive can be turned off. However, this cohesion can in principle also result, as indicated, when the same or the same adhesive is used as a connection between the second and first layer and as a binding agent for the second layer.

Due to the fact that the adhesive is increasing in volume, in the course of hardening, it is possible to proceed favorably by hardening under pressure, ie at least with movement hindrance transversely to a surface extension of the plate body formed in this way, possibly also by additional pressure reduction of a thickness of the layers in one from an initial state, so that the adhesive increasing in volume is forced to penetrate into gaps and surface areas of the mutually facing surfaces of the first and second layer, in particular the second layer, and / or to closely enclose three-dimensional structures of the respective surface . In this way, it is also possible to achieve favorable clamping in addition to the adhesive effect itself. This can take place during the manufacture of the panel body in the course of a gluing / connection of the mineral granulate bodies that only then begins, so that the adhesive, which increases in volume, can penetrate comparatively easily, at least superficially, into the area of the second layer. In the event that the binding agent also consists of the adhesive that increases in volume when it cures, mutual penetration can also take place through it.

Insofar as the second layer is introduced into a mold as a bed, possibly a bed already provided with the binding agent, the application of pressure is geared towards reducing the total volume (initial volume) of the plate body, with the volume being reduced in particular on the second layer , the granulate layer, relates and is between 30% and 50%, preferably in the range of 40%. The pressure required for this must then be applied. This volume reduction corresponds at the same time to an equal reduction in thickness, that is to say also between 30% and 50% based on an initial thickness. A reduction in the total volume through the application of pressure is advantageous, on the one hand, with regard to stability of the bed compacted in this way or, ultimately, of the plate body made from it. On the other hand, this also results in an increasingly lower tendency of the plate body to absorb moisture, in particular water. This can be advantageous with regard to subsequent work steps, in particular in the case of panel bodies which have already been completed as such and which are optionally carried out with the addition of water.

With regard to the third layer, a fabric layer, for example a layer of glass fiber fabric, can be provided. This can be mixed with an adhesive referred to here as a binder, for example a resin. With regard to the formation of the fabric, an anisotropy can also exist in a preferred embodiment, such that, for example, stronger fibers are used in the longitudinal direction of the worktop than in the transverse direction.

Particularly when used as a door, it is preferred that the third layer is designed in the same way as the first layer, that is, it consists of a natural stone presenting a stone-like surface, a ceramic material, a quartz composite or some other stone-like material. A plate body produced in this way is preferably constructed mirror-symmetrically with respect to a longitudinal center plane. In particular when used as a door, the panel body can also be made of a solid material such as wood in particular, but possibly also plastic, on the edge to form a narrow side and in particular its outer surface. This solid material can be embedded in the panel body in the form of a bar. For this purpose, a corresponding partial area of the second layer can preferably be removed, for example milled out, and this solid body part then inserted. For example, it can then also be glued to the second layer again.

It is preferred that the solid body part is only located within the second layer or only areas of the second layer are worked out, for example milled out, in order to create the space for the solid body part. It is also preferred that the solid body part directly touches the second layer, or optionally also the first layer or the third layer, further optionally also the fourth layer over a practically full cross-sectional area, so that there is practically no cavity between the solid body part and the one in question Location is given.

The third layer is preferably also connected to the second layer or at least to the layer located above it by means of an adhesive which increases in volume during the course of curing. It can be the same PU adhesive that is used between the first and second layer for connection.

The glass fiber fabric itself can already be present as a finished panel body during processing into the panel body described here. It can be a comparatively thin glass fiber fabric plate body, for example with a thickness between 0.5 mm and 1.5 mm, more preferably between 1.0 mm and 0.6 mm and furthermore preferably between 0.9 mm and 0 , 7mm thickness. The first and / or third layer can be connected directly to the second layer. Alternatively, however, it can also be provided that the first layer is connected to the second layer by means of a fourth layer, an intermediate layer, the fourth layer being connected to the second layer by means of the adhesive which increases in volume in the course of curing, the In this case too, adhesive is present comprising a three-dimensional surface structure of the second layer and the binder of the second layer forms or is also different from the binder of the second layer.

In this case that a fourth layer is provided, the connection between the first layer and the fourth layer can be provided by means of a customary adhesive, for example epoxy resin adhesive, but the connection is also preferred by means of the aforementioned during curing in the Volume-increasing adhesive connected.

The fourth layer can, however, also preferably be designed in the form of a coarse-meshed fabric, or at least in a cross structure in which free spaces (holes) remain. In this case, despite the arrangement of the fourth layer, there is a direct connection between the first layer and the second layer, as it were with penetration through the fourth layer, also in this case by means of the adhesive, which increases in volume during curing, as at the beginning described.

Insofar as an adhesive increasing in volume is described above and below, it is preferably designed as a foaming adhesive.

Figure list

• 1 ein schematisch dargestelltes Küchenmöbel mit einer darauf befindlichen Arbeitsplatte;
• 2 einen Ausschnitts-Längsquerschnitt durch die Arbeitsplatte des Küchenmöbels gemäß 1;
• 2a eine Nischenauskleidung;
• 3 einen nochmals vergrößerten Ausschnitt aus dem Längsschnitt gemäß 2 im Bereich III;
• 4a-h eine schematisch wiedergegebene Abfolge einer ersten Herstellmöglichkeit des Plattenkörpers; wobei
• 4a eine Form im Ausgangszustand, ungefüllt, zeigt;
• 4b die Form gemäß 4a nach Einlage der ersten Lage;
• 4c die Aufbringung von Klebstoff auf die erste Lage;
• 4d die Form gemäß 4a mit der eingelegten ersten Lage und dem weiter eingebrachten Granulat, bei Aufbringung eines Bindemittels für das Granulat;
• 4e alternativ oder ergänzend die Aufbringung einer weiteren Lage Klebstoff auf die Granulatschicht, gegebenenfalls auch auf die dritte Lage;
• 4f die Aufbringung der dritten Lage auf das Granulat;
• 4g bezüglich der Variante bei Ausbildung einer Tür oder dergleichen Aufbringung einer dritten Lage auf die Lage Klebstoff gemäß 4e; und
• 4h die Volumenverringerung einer gefüllten Form im Hinblick auf die Granulatlage, hier mit einer Druckplatte, die mit einem Druckstempel beaufschlagt wird;
• 5a-b eine Darstellung gemäß 4, einer zweiten möglichen Herstellung des Plattenkörpers; nämlich
• 5a die erste Lage, die mit Klebstoff versehen ist, wird ein gesondert vorgefertigter Granulat-Plattenkörper aufgelegt; und
• 5b auf die Zusammenfassung des Granulat-Plattenkörpers und der ersten Lage wird die dritte Lage aufgelegt;
• 6 eine schematische Ansicht einer Tür;
• 7a-b eine Tür in Schnittansicht, nämlich
• 7a einen ersten Schnitt durch die Tür gemäß 6, geschnitten entlang der Linie VIIa-VIIa; und
• 7b einen zweiten Schnitt durch die Tür gemäß 6, geschnitten entlang der Linie VIIb-VIIb.

The invention is further explained below with reference to the accompanying drawing, which however only represents an exemplary embodiment. Here shows:

• 1 a schematically shown kitchen furniture with a worktop on it;
• 2 a cutout longitudinal cross-section through the worktop of the kitchen furniture according to 1 ;
• 2a a niche lining;
• 3 a further enlarged detail from the longitudinal section according to 2 in area III;
• 4a-h a schematically reproduced sequence of a first manufacturing possibility of the plate body; in which
• 4a shows a shape in the initial state, unfilled;
• 4b the shape according to 4a after inserting the first layer;
• 4c applying adhesive to the first layer;
• 4d the shape according to 4a with the inserted first layer and the further introduced granules, when applying a binding agent for the granules;
• 4e alternatively or additionally, the application of a further layer of adhesive to the granulate layer, possibly also to the third layer;
• 4f the application of the third layer to the granules;
• 4g with respect to the variant in the formation of a door or the like application of a third layer to the layer of adhesive according to FIG 4e ; and
• 4h the volume reduction of a filled mold with regard to the granulate layer, here with a pressure plate to which a pressure stamp is applied;
• 5a-b a representation according to 4th , a second possible manufacture of the plate body; namely
• 5a the first layer, which is provided with adhesive, is placed on a separately prefabricated granulate plate body; and
• 5b The third layer is placed on the combination of the granulate plate body and the first layer;
• 6 a schematic view of a door;
• 7a-b a door in sectional view, namely
• 7a a first section through the door according to 6 , sectioned along the line VIIa-VIIa; and
• 7b a second section through the door according to 6 , sectioned along the line VIIb-VIIb.

Description of the embodiments

On the basis of a first example of a worktop produced from a plate body, as is basically concerned here 2 of kitchen furniture 1 , and a second example relating to a door 16 , the invention is further explained.

A kitchen furniture 1 , see. 1 , can be a countertop 2 exhibit. It can be kitchen furniture 1 act as it is used in a common household kitchen. In addition to a cheek on the worktop, see the explanation below 2a A conventional niche lining, which is not shown in detail, can also be provided by a plate body, as described here.

In addition, a plate body of the type described here can also be provided in other areas, not even limited to a kitchen.

With regard to the niche lining, a panel body, as described here, can be used which has a significantly smaller thickness, for example one third, half or up to two thirds the thickness of a conventional kitchen worktop. The thickness of a conventional kitchen worktop can be set in the range of 38 mm. Correspondingly, the plate body can also have a small thickness of (only) 13 mm.

For other applications, it can also be a significantly thicker plate body, for example up to a thickness of 100 mm. A preferred range of possible thicknesses is therefore between 16 mm and 100 mm.

The countertop 2 has a multilayer structure, as described in more detail in 2 can be found. In 2a is a typical further processing of the plate body, as it is also basically in 2 is shown, shown on a worktop with a cheek, which is attached here as a miter part.

With regard to the plate body or, specifically, the worktop, a surface is an outer surface in use 3 forming first layer 4th intended. At the worktop 2 is the location 4th also the top layer when in use. For example on a door 16 is the location 4th and the location 6 one outer layer each, extending vertically when in use. Under the situation 4th there is another, second layer 5 and as - in the embodiment of the worktop - the lower end of another, third layer 6 .

The upper layer 4th , which represents the work surface of the countertop, has a stone-like character.

The locations 4th , 5 and 6 are preferably provided directly adjacent to one another, only connected by an adhesive layer. The adhesive layer is also preferably made of adhesive only as such 7th existing without a structural layer or that it would be formed on the basis of a prefabricated film layer, provided. The use of a prefabricated film layer with regard to the adhesive 7th is, on the other hand, possible in principle, for example, as will be explained further, if heating is used in the production process and the adhesive is liquefied in the process 7th can arise again. The adhesive layer can be very thin. It can also be given that the locations 4th and 5 in the above areas, especially with regard to the granulate, possibly the expanded glass parts, see below, are directly adjacent to one another and there is no or only a very thin layer of adhesive between them, which can then be thickened again in the further area. Thus, the thickness of the adhesive layer can vary between, for example, 2 mm and 3 mm and practically no thickness, such as 0.1 mm or 0.2 mm, over the area.

The second layer 5 consists in the embodiment of a mineral granulate, which is selected here as expanded glass granulate. The expanded glass granulate is connected to an independent body by means of a binding agent, which is preferably a PU adhesive, but can optionally also be an epoxy resin. In this case, this body can also only arise in the course of production or it can be applied as a separate plate body in the course of production, as will be described in more detail below. As already explained above, the binding agent can also be formed by an adhesive that increases in volume during curing, in particular the same or the same adhesive that also preferably provides the adhesive connection between the first and second layers.

With regard to the mineral granulate, ie preferably the expanded glass granulate, a spherical shape of the granulate bodies is preferred, as already noted. The diameter range can be, for example, from 0.01 mm to 4 mm. It is preferred that a plurality of fractions are correspondingly mixed. For example three to six fractions, preferably five fractions, each fraction having a significantly different mean size of the diameter of the granulate parts. For example, the first fraction in the range of 0.01 mm, the second at 0.1 mm, the third at 1 mm, the fourth at 2 mm and the fifth at 3 mm and the sixth at 4 mm. The closed shape of the granulate body, in particular a spherical closed shape, in the case of a hollow body shape of the granulate body as such, is also important with regard to the low weight sought in particular. Preference is given to using approximately or practically 100% closed granulate parts.

Between the first layer 4th and the second layer 5 is preferably an adhesive that increases in volume in the course of curing 7th as an adhesive layer 8th arranged. The adhesive 7th is in the cured state, as it is with a finished worktop 2 is given, a three-dimensional surface structure of the second layer closely before comprehensively. This is detailed on 3 to refer in which the attempt is made to reproduce this graphically. In particular, the adhesive is a foaming adhesive.

The lower, third layer 6 is a comparatively thin layer in the first embodiment, which is formed as an underlay. The third layer 6 can through another layer of adhesive 8th with the second layer 5 be connected. The adhesive layer 8th is also preferably an adhesive layer 8th from an adhesive that increases in volume during curing 7th . The PU adhesive already mentioned is also particularly preferred here.

In the exemplary embodiment, there is the third layer 6 made of a resin-impregnated fabric, which after application to the underside of the second layer given in the state of use 5 is preferably caused to harden and bond by controlling or adding moisture and / or by developing heat. The humidity can be regulated on the one hand by the processing status of the object, the fabric and / or the second layer 5 , be self-controlled, i.e. through their moisture content. On the other hand, alternatively or in addition, through a targeted addition of moisture, for example by spraying water. In the same way, however, the second layer can also be used 5 the third layer 6 can be applied as an independently prefabricated panel in the course of production. In particular, this also applies to this third position 6 preferred that a the rigidity of the third layer 6 the resulting binder is different from the adhesive 7th with which the adhesive layer 8th is formed. Alternatively, however, the binder can also be made from the adhesive in this variant 7th be educated.

In addition or as an alternative to the third layer 6 In the form of a backing layer, in the embodiment described, a third or, if necessary, fifth layer can also be used 6 in the same training as the first layer 4th be provided. The third or fifth layer exists accordingly 6 in this case, see also 6 to 7th , made of a stone-like surface presenting natural stone, a ceramic material or a quartz composite.

In reference to 6 is a door 16 shown, which consists of a plate body with a structure, as for example in the 7a and 7b is reproduced, is preferably formed.

To do this, the procedure is evident that the door 16 is formed symmetrically to a longitudinal center plane EE in structure. In the 7a and 7b the longitudinal center plane is cut horizontally, correspondingly reproduced as a line. This symmetrical structure can possibly with the exception of a hinge-side or opposite longitudinal edge area - based on an installed state of the door 17th and / or an upper and / or lower front edge 18th , 19th the door 16 be given. The special design of the longitudinal edge area or areas, if applicable, as described 17th and / or the upper and / or lower front edge 18th , 19th is preferred after a production of the plate body semi-finished product, such as in relation to the 4th and 5 described, made on a door part formed therefrom. A depth measured horizontally in relation to the installation condition t of the longitudinal edge area 17th can in terms of an overall height H the door 16 be a fraction, for example a tenth or less of the total height. In absolute terms it can be a depth t of a few centimeters, for example 2 cm to 10 cm.

What is not shown in detail, but is also possible, is that a corresponding training according to 7a or preferably in this case according to 7b , on one or both upper front edges 18th , 19th is also provided.

With regard to a longitudinal edge area 17th the door 16 is preferably in the second layer 5 a solid part 22nd let in, which preferably wholly or at least partially longitudinal surfaces 20th or 21st forms. With the solid part 22nd it can be a wooden part or, for example, a solid plastic part. The solid body part can, for example, part as aluminum, in principle also with an inner opening, that is to say as a chambered part.

It is also preferred that the solid body part 22nd in the cross-section shown, a towards the inside of the door 16 down has tapered shape, which is preferably wedge-like. In the case of a specific wedge shape, opposite wedge surfaces inclined towards the plane EE result 23 , 24 .

The solid body part 22nd can in the same way as explained further above for the gluing, with an adhesive, that is, preferably a PU adhesive, with the second layer 5 be glued.

It can be provided that, preferably in the contact area between the second layer 5 and the first layer 4th , a reinforcement layer 25th is inserted, which also preferably extends only over one of the extent of the solid body part 22nd in the depth direction corresponding to the height proportion of the door 16 extends. This underlay layer can serve to reinforce the weakening of the second layer in this area 5 due to the solid body part used 22nd .

The reinforcement layer, which is also to be referred to as the fourth layer, can optionally also be used as a completely continuous reinforcement layer 25th be trained. Here, a preferred embodiment is given according to the fourth layer described above, for example also in the form of a lattice material, such as a coarse-meshed fabric, for example a coarse-meshed glass fiber fabric, which allows the first layer despite the presence of a fourth layer 4th with the second layer 5 to connect directly via the adhesive mentioned. As a further alternative, the fourth layer can also be designed as a closed layer, with the direct connection between the fourth layer and the second layer via the adhesive increasing in volume 5 .

In terms of production, the procedure is preferably such that initially the first layer 4th will be produced.

In the event that the first location 4th consists of a natural stone, a natural stone that is usually sawn in this respect is present. The thickness of the natural stone is preferably selected to be small, preferably in the range from 1 mm to 12 mm, more preferably in the range from 3 mm to 10 mm.

With reference to the 4a to 4h a first possible manufacturing method of a plate body, as it is concerned here, is shown schematically.

First, a rectangular, open-topped shape is made 9 provided, the rectangular inner dimensions are adapted to the preferred dimension of the panel body to be produced. For example, it can be a length 1 of about 3 m and a width b act from about 1.5 m.

In the form 9 , please refer 4b , is then the first layer, preferably with the later outer side down 4th , for example a natural stone slab, inserted. On this situation 4th , the back of which in the exemplary embodiment is preferably in liquid form, see 4c , the adhesive that increases in volume when it hardens 7th upset. It is preferably a closed and more preferably essentially liquid adhesive layer made of adhesive 7th .

This adhesive layer is then, see 4d , a mixture of mineral granules 10 , in the exemplary embodiment thus an expanded glass granulate, applied as a bed. A fat one d can be made slightly larger than the final thickness of the second layer that is created later 5 corresponds. This is due to the possible infeed movement, which will be explained below, when pressure is applied, which can optionally be provided in addition to a mere movement hindrance.

The bed of granules is further coated with a binder 11 provided, which is shown here as poured only for explanation. The binder 11 can also be done with the granules beforehand 10 have been mixed.

On the layer-like bed of granules formed in this way 10 will then, see 4e and 4g , the third layer 6 applied, previously on its flat side facing the layer-like bed in the installed state with a layer of adhesive 7th was provided, also in this case preferably as a closed, more preferably essentially liquid adhesive layer.

To this -. further - adhesive layer made of adhesive 7th will then, see 4f , the third layer 6 , in the form of a glass fiber fabric in the embodiment. This glass fiber fabric or the third layer 6 as such, a further binder can be added independently, but can still be rollable, for example. In the course of further production, this adhesive (binder) also hardens. The third layer 6 can also already be in the form of a rigid fabric sheet body and as such can only be placed in the mold, as described, preferably with this third layer 6 applied adhesive layer. If necessary, the location 6 but can also be placed on a layer of adhesive previously applied to the bulk granulate in the mold.

Alternatively, see 4g , can be used as a third layer 6 in turn a natural stone plate, for example, or a ceramic plate or a plate made of a quartz composite or some other stone-like material can be applied.

The form filled in this way is then 4h , by means of a pressure plate 12 that corresponds to the open inside dimension of the mold 9 is adapted and, for example, with a pressure stamp 13 can be acted upon, pressurized. This pressurization can on the one hand consist solely of an impediment to movement, since the pressure then increases as a result of the adhesive increasing in volume during curing 7th adjusts. In addition, by means of the pressure stamp and a certain method of an infeed movement of the pressure stamp, but also a supplementary pressure force can be applied.

The movement of the pressure stamp in the sense of an infeed movement is preferred. In this case, the method is carried out to such an extent or to such an extent that the required pressurization also results accordingly that the initial volume or an initial thickness of the plate body thus formed is significantly reduced. Preferably in the range of 20% or more, for example 30% to 50%. This means that the resulting thickness of the plate is only 70% to 50% of the initial thickness, preferably in the range of 60%.

In an alternative production method, as shown in the 5a to 5c is shown, instead of applying the granulate layer according to 4d , please refer 5a , a prefabricated granulate plate body 14th used. The granulate plate body 14th can beforehand itself in a corresponding form, then only with regard to the production of the granulate plate body itself, for example in accordance with the above with reference to 4d explained, be produced. The prefabricated granulate plate body 14th is also applied to the first layer according to this manufacturing method 4th upset. Here, too, is the situation 4th beforehand with a layer of glue 7th been provided. Regarding the application of the layer of adhesive 7th In principle, reference can be made to the manufacturing method described above. In the alternative production method, too, it is preferred, for example also by moving a pressure ram, in the previously given production of the prefabricated granulate plate body 14th a thickness reduction, to the extent as also described for the first production method, has been made. According to this method of production, a corresponding pressure is applied in order to create the tightly encompassing bond between the first layer, which can also be referred to as clip-like 4th and the prefabricated granulate plate body 14th to reach. Preferably, as already described above, using the volume which increases during curing.

After method step 5a, the third layer can, in accordance with method step 4f 6 , which is present in rollable form, for example, are applied.

According to 5b is an alternative to the manufacturing step according to 4f preferably a finished fabric sheet body 15th used. This tissue plate body 15th is hardened like a plate due to the binder already contained in it and can therefore be handled as such. In this production method, it is alternatively also possible to produce the third layer by using a fabric that can still be rolled, for example.

As a further alternative to method step 4f, the method step according to FIG 4g the same plate body as he did for the first layer 4th is given to form a third layer 6 , preferably also using a corresponding further layer of adhesive.

Otherwise the procedure is the same as with regard to 4a to 4h explained.

The manufacturing step according to 4h can, in addition to the developing or exerted higher pressure, in particular also be carried out at an elevated temperature. In this way, in particular, the curing can be accelerated, so that short cycle times in production can be achieved in some areas. The increased temperature can be in the range from 40 ° C. to 170 ° C. or higher, preferably in the range from 100 ° C. to 150 ° C., for example.

In the 4b to 4g the shape is only shown cut open to make the layers easier to see. The procedure actually used is preferably always a closed form, for example in 4a or 4h is reproduced.

In particular, if an adhesive is used that does not depend on a property that increases in volume, but also when an adhesive with a property that increases in volume is used, the insertion can also, as shown, in the case of prefabricated plate parts be completely or largely dispensed with in one form.

Due to the hindered evasiveness of the layers due to the pressure 4th and 5 or, if appropriate, the described volume reduction is achieved so that the adhesive spreads out closely encompassing the three-dimensional surface structure of at least the second layer and thus, in addition to gluing, can also achieve a kind of clamping.

To complete the worktop, the plate body is milled and polished on the outside with respect to the layer of natural stone, for example. Edge gluing or other edge processing and also cutting can also be carried out.

All of the features disclosed are essential to the invention (individually, but also in combination with one another). The disclosure of the application hereby also fully includes the disclosure content of the associated / attached priority documents (copy of the previous application), also for the purpose of including features of these documents in the claims of the present application. The subclaims characterize, even without the features of a referenced claim, with their features independent inventive developments of the prior art, in particular in order to make divisional applications on the basis of these claims. The invention specified in each claim can additionally have one or more of the features provided in the above description, in particular provided with reference numbers and / or specified in the list of reference numbers. The invention also relates to design forms in which some of the features mentioned in the above description are not implemented, in particular if they are recognizable for the respective purpose or can be replaced by other technically equivalent means.

List of reference symbols

1

kitchen furniture

2

Countertop

3

Exterior surface

4th

Location, first

5

Location, second

6th

Location, third

7th

adhesive

8th

Adhesive layer

9

shape

10

granules

11

binder

12

printing plate

13

Stamp

14th

Granulate plate body

15th

Tissue plate body

16

door

17th

Longitudinal edge area

18th

Front edge

19th

Front edge

20th

Longitudinal surface

21st

Longitudinal surface

22nd

Solid body part

23

Wedge surface

24

Wedge surface

25th

Reinforcement layer

b

width

d

thickness

1

length

t

Depth section

H

height

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 19519116 A1 [0005]
• DE 102011108996 B3 [0006]
• DE 102010034851 B4 [0006]
• DE 102010003236 U1 [0006]
• EP 1153738 A1 [0007]

Claims (11)

Plate body with a multi-layer structure, with a first layer (4), which in use forms an outer surface, consists of a ceramic material, natural stone, a quartz composite or some other stone-like material that presents a stone-like outer surface, a second layer (5), which is below the first layer (4), consists of a mineral granulate joined to form a body by means of a binding agent and a third layer (6) which is arranged below the second layer (5), characterized in that the first layer (4) is directly connected to the second layer by means of an adhesive (7) which increases in volume in the course of curing, the adhesive (7) closely encompassing a three-dimensional surface structure of the second layer (5) and different from the binding agent of the second layer (5) ) or also forms the binder of the second layer (5). Plate body with a multi-layer structure, with a first layer (4), which in use forms an outer surface, consists of a ceramic material, natural stone, a quartz composite or some other stone-like material that presents a stone-like outer surface, a second layer (5), which is below the first layer (4) consists of a mineral granulate joined to form a body by means of a binding agent and a third layer (6) which is arranged below the second layer (5), characterized in that 50% or more of the granulate is spherical granules and the spherical granules are present in fractions of different diameters, a fraction with a proportion of 10% or more, up to, for example, 90% of the granules, having a diameter of 1 mm or less, that the first layer (4) is connected to the second layer by means of an adhesive (7) which increases in volume during curing, the adhesive (7) being a The three-dimensional surface structure of the second layer (5) is closely encompassing and is different from the binding agent of the second layer (5) or also forms the binding agent of the second layer (5). Panel body according to one of the preceding claims, characterized in that the third layer (6), which is also glued to the second layer (5), is designed as a thinner underlay layer which can be handled independently with the further layers. Plate body according to one of the Claims 1 or 2 , characterized in that the third layer (6), like the first layer (4), consists of a natural stone presenting a stone-like outer surface, a ceramic material, a quartz composite or some other stone-like material and / or, preferably, that the second layer (5) is formed from expanded glass parts. Plate body according to one of the preceding claims, characterized in that the granulate parts of the mineral granulate and / or the expanded glass parts are spherical and / or, preferably, that the granulate is in the form of a mixture of granulate bodies of different sizes and / or, preferably, that the binder is a PU -Adhesive and / or, preferably, that the binder is a resin, wherein, preferably, the binder is an epoxy resin. Panel body according to one of the preceding claims, characterized in that the third layer (6) is a fabric layer and / or, preferably, that the third layer (6) has a glass fiber fabric and / or carbon fiber fabric or the like and / or, preferably that the The adhesive increasing in volume is a PU adhesive and / or, preferably, that the panel body is used as a worktop of kitchen furniture (1) with appropriate finishing and / or, preferably, that the first layer (4) and / or the third layer (6) is directly connected to the second layer (5). Panel body according to one of the preceding claims, characterized in that the first layer (4) is connected to the second layer (5) by means of a fourth layer, an intermediate layer, the intermediate layer by means of an adhesive which increases in volume in the course of curing ( 7) is connected to the second layer (5), the adhesive (7) having a three-dimensional surface structure of the second layer (5) closely encompassing and forming the binding agent of the second layer (5) or also being different from the binding agent of the second layer ( 5). Panel body according to one of the preceding claims, characterized in that the panel body is designed as a door (16), wherein, preferably, an end face is formed by an inserted solid body part (22), in particular a wooden part, wherein, more preferably, the solid body part ( 22) is only used in the area of the second layer (5) and / or the solid body part (22) tapers towards the inside of the door, preferably tapering in a wedge-like manner, in this case with one or two opposite one another towards the interior of the panel body and in the surface direction of the panel body Wedge surfaces (23, 24) is formed. Method for the production of a plate body with a multilayer structure, wherein a first layer (4), which in use forms an outer surface, consists of a natural stone presenting a stone-like outer surface, a ceramic material, a quartz composite or other stone-like material, a second layer ( 5) under the first layer (4), consists of mineral granules connected to form a body by means of a binding agent and a third layer (6) which is arranged below the second layer (5), characterized in that on a rear side of the first layer ( 4) an adhesive (7) which increases in volume in the course of curing is applied and then a granulate layer is applied which has a binding agent that can also be provided by the adhesive or is different from the adhesive (7) and that the granulate layer is connected to the first layer (4) under the action of pressure. Procedure according to Claim 9 , characterized in that a third layer (6) is applied to the second layer (5) before the application of pressure, wherein, preferably, the third layer (6) is glued to the second layer (5), wherein, preferably, the third Layer (6) is glued to the second layer (5) by means of an adhesive (7) that increases in volume during curing. Method according to one of the Claims 9 or 10 , characterized in that the second layer is applied in the form of a bed of mineral granulate parts or that the second layer is applied in the form of a prefabricated granulate plate.

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