DE202006009793U1 - Method for stabilizing thin stone or ceramic panels using carbon fiber matrix and carbon fiber stone support layer - Google Patents

Abstract

A method for stabilizing thin stone or ceramic panels has the panels backed by a carbon fiber stone supports as well as a carbon fiber matrix. The matrix can be based on resins, e.g. epoxy, melamine, polyurethane etc. The thin panels can be further protected by thin strips of carbon fiber prior to applying the support layers.

Description

The The present invention relates to the stabilization of earthenware in the broader sense, that is Natural stone, artificial stone, concrete and other earthenware, as well as ceramics to glass-containing substances - in the following earthenware called - by a brittle and at risk of breakage Structure are marked. Here are especially natural stones such as granite, granite-like Rocks such as gneiss, marble, limestone, high-strength modern ceramics, To mention glass ceramic or glass, and all other stone or ceramic materials, natural or artificial created earthenware, which are usually high pressure resistant.

These On the one hand, materials are characterized by a high load capacity under pressure, however, are almost completely unstable at Tensile and bending load, especially if possible thin and should be designed to save material.

there are mainly thin stoneware slabs, which are increasingly used in facade construction and as a table and Worktops serve, but also in other areas, such as the furniture or Armaturenbau, as stairs, wall coverings and floor tiles be used.

The present invention proposes a way to such thin designed earthenware or ceramic or artificial stone slabs sustainably stabilized in a cheap way so. To this, too it is absolutely necessary to reach it the earthenware or ceramic plates against train and associated Stabilize breakage. Such a way suggests the invention. The way guaranteed that both Stone, as well as ceramics among the most diverse mechanical Loads are stabilized so that they through one, for the respective Use and load cases suitable, stabilization against mechanical destruction on the one hand, but in particular also be protected against thermal destruction. At the same time, dimensional stability is of central importance Importance.

A essential property of the composite of this described Materilien is the resistance to geometric change due to thermal stress, as well as the destruction and freedom of deformation of the stone or ceramic in shock.

core the solution, that for thin stone slabs at the To find the most suitable Stabilisierungsmatel it is, stone itself to use it, namely stone, which is itself protected against breakage. Goal of the solution should be, possible to use little carbon fiber material without resorting to a sustainable To renounce stabilization. This requirement becomes the core of Invention.

The Invention is based on the stabilization of stone or ceramics through a plane carbon fiber-based carrier material attached to the stone, which allows that for the stabilization of thin Needed stone materials Earthenware material as possible thin or easy to keep and material-saving.

Known are previously lightweight designs in which as in this new invention also one possible thin natural stone layer flat by a substructure of different carrier materials and carrier forms, like frames and the like Strengthen constructions and thus made resilient, or only allows stone slabs correspondingly thin perform. The carrier material is usually chosen from the point of view, that it with sufficient mechanical strength, mainly from the use of conventional ones Materials such as steel and aluminum is intended.

It For example, corrugated or honeycomb-shaped metal or aluminum sheets as a carrier material used a thin stone layer of 2-3mm after abrading of the original 20 mm thick material remains on this carrier. A similar Stabilization method is the use of glass fiber or Aramid fiber laminates stabilizing the stone, the stabilizing layer however, at most has the same coefficient of expansion as the stone to be stabilized. The result is a pressure- and tension-loadable plate, in normal use cases adequate stabilization of the stone for cladding applications in the Interior supplies, but already at changing and in particular rising temperatures do not provide adequate protection against breakage offers more.

In these cases Improved stabilization of the stone disc is necessary also non-destructive to the thermal / mechanical load case for the stone safeguards.

By The prior art describes components made of stone or ceramic, to absorb extreme thermal-static and thermal-dynamic loads have to to stabilize with carbon fibers.

The task of safely counteracting the tendency of thin natural stone and / or ceramic plates to break or crack is solved by improved stabilizing properties of the carrier. For this purpose, a carrier material is inserted sets, which has an equal or slightly lower coefficient of expansion than the stone plate to be stabilized.

The Support material in the following carrier called, consists of a fiber-reinforced matrix, which is a synthetic resin or optionally itself is a ceramic material. It comes here Carbon fibers are used to withstand high tensile loads and under heat contract, so a negative coefficient of thermal expansion own and stabilize a more or less long stone rod, stabilized as stabilizer of the stabilizer itself Earthenware plate is. As a result, the plate is especially against cracks by overstretching and heat protected, as well as the break by mechanical load perpendicular to the earthenware counteracted.

Thin flagstones, For example, facade cladding, in particular by the invention under thermal stress and the associated carrier material expansion, which cause cracks or surface fractures of the lead worn stone material would, safely protected against cracking. The usual arising, under circumstances microscopic hairline cracks leading to the rapid decay of the stone to lead, especially when he is constantly changing outdoors Temperatures, water and frost is exposed by the Invention complete locked out. Even thinnest Stone slabs can produced by means of the invention while maintaining its stability be without distracting to break. Also the mechanical stress, the pressure load exercised vertically on the stone be intercepted without strain, to the stone against the same Cracking as described above to protect. Especially the expansion of the carrier material by thermal action is not greater than that of the stone itself. This avoids that thin stone material pulled apart by the support bars becomes.

With Help of the use of, for example, stable epoxy resins, polyester resins, Resins on phenolic, polyimide, cyanate, melamine, polyurethane or silicone base, called matrix, in combination with carbon fibers, which have a negative coefficient of thermal expansion becomes such a safe stabilization of stone rods, which in turn stabilize the earthenware plates are possible. Characteristic here is that the Fiber composite a negative coefficient of thermal expansion Has. extraordinarily helpful for An optimal connection between stone and fiber composite is included the porous one and thus absorbent consistency of stone. A resin can formally become suck the stone and leads so to an enormously stable connection between stone and the Stone stabilizing laminate. It is important that the resin in terms of its viscosity optimally the absorbent properties of the stone to be stabilized is adjusted. The mutually stabilizing components then "merge" downright.

Of the So stone can be non-destructive be bent within certain limits. This important property of Steins, namely destructively be compressible, in combination with the heat load astringent and extremely tear-resistant carbon fiber, which is an overstretching of the Steins counteracts provided the two components firmly together are connected, becomes the subject of the invention and the realization the use of such components, even for dynamic load cases.

It gets over it addition to the requirement, the mechanical strength and temperature resistance of thin to thinnest To optimize stone cladding so that the overall coefficient of expansion the plate can be reduced to zero in wide temperature ranges can, even with exterior facades a non-destructive, this means to achieve expansion-free stabilization. So that one at a building wall attached, seamless exterior facade may arise, the stone plate may under heat do not stretch. The stone learns in that he through the carrier plate at Strive for warmth is prevented, a very high internal pressure. Like executions However, according to the invention, natural stones such as e.g. Granite but so insensitive to pressure that this Compulsion does not hurt the stone, surprisingly, even then, when the stone is completely stabilized by a thermal conditional expansion is hindered. This realization is perfect new, is only observed with very few materials and becomes so as well to the essence of the invention as the rarely observed negative thermal expansion coefficient of carbon fiber. Here is the Core of the reasons to find for that why the two materials in conjunction so useful good Achieve result and complement each other in such an ideal way ..

The Invention is thus realized by the use of carbon fiber reinforced stone rods, the thin earthenware plates stabilize.

The Earthenware is so on external force in general and also on temperature influence in particular the complementary The expansion counteracting force passing through the carbon fiber stone (CFS) carrier achieved is, mechanically forced to remain dimensionally stable and stable. she do not get the slightest chance of cracking.

A another variant is the use of earthenware plates that partially, stabilized with a layer of carbon fiber backing.

One The main advantage of this invention is that the carbon fiber is material saving by the arrangement described here.

Of the Another very important further advantage is that the slab of stone slab and carbon fiber stone tanner working extremely well and dimensionally stable, i. cut and mill, and especially at different temperatures. stole in contrast, only if he has the desired length at the same Temperature is cut, which prevails during later use.

One of the many possible embodiments of the invention describes a rectangular bar of stone ( 1 ), which on both sides with a carbon fiber roving ( 2 ) is stabilized ( 1 ). The connection between stone and fiber is produced by a temperature-stable epoxy resin matrix, which can be thermally stable depending on the field of use.

The resulting carriers ( 3 ) are placed under a stone slab ( 4 ) firmly bonded, which is thus sustainably stabilized carbon fiber saving.

2 shows this second embodiment of the invention as a more or less large thin stone slab ( 1 ) partially covered on the underside by a layer of carbon composite fiber ( 2 ), which is additionally stabilized with CFS rods.

3 shows a flagstone ( 1 ), whose rim is made of CFS rod, which is placed between two staves ( 2 ) a carbon fiber layer ( 3 ) contains. All three versions described above can also be used mixed depending on requirements and load case.

Claims (5)

Arrangement with a plate or other geometry made of stone, natural stone, stoneware, artificial stone, concrete, ceramics, glass-containing material, hereinafter referred to earthenware, which on one or both sides by a stone rod consisting of stoneware and carbon fiber material and matrix, in the following carbon fiber stone carrier ( CFS support) is stabilized, characterized in that the CFS carrier carbon fiber matrix, the matrialsparend one or both sides on the CFS carrier or preferably as a layer in the middle of the CFS carrier is attached. Arrangement according to claim 1, characterized that the Matrix of the carrier an epoxy resin, polyester resin, phenolic resin, polyimide resin, cyanate ester resin, Melamine resin, polyurethane resin or silicone resin base has. Arrangement according to claim 1, characterized that the Matrix has a ceramic or waterglass base. Arrangement according to claim 1, 2 and 3, characterized that the carrier a mixture of different additional fiber materials in a layer contains or of several layers, each with different fiber materials consists, or a mixture thereof is included. Arrangement according to Claims 1 to 4, characterized that the thin stone plate with more or less thin Strip of carbon fibers is pre-stabilized.