DE202006018135U1 - Stone plate, eg natural stone, is stabilised using a matrix carrier that contains a fibre material, where the plate and carrier are 8.9999 - 9.9998 mm thick - Google Patents

Abstract

A stone plate (1), eg natural stone, synthetic stone, concrete, ceramic, or glass material, is stabilised using a carrier matrix (2) containing a fibre material. The plate and carrier are 8.9999 - 9.9998 mm thick. The carrier contains carbon fibres.

Description

The The present invention relates to the stabilization of as possible thin Plates of natural stone, artificial stone of all kinds, concrete and other earthenware, as well as ceramics up to glass-containing substances - in the following Stone or earthenware called - the through a brittle and at risk of breakage Structure are marked. Here are especially natural stones like Granite, basalt, granite-like Rocks such as gneiss, as well as marble, limestone, high pressure resistant modern Ceramics, glass ceramic or glass to mention, as well as all other Materials of stone or ceramics, natural or artificial created earthenware, which are usually high pressure resistant.

These Materials are referred to below as stone or stoneware. On the one hand, they are characterized by a high load capacity under pressure, however, are almost completely unstable at tensile and bending load, especially if you want to thin and material-saving, philigran and especially lightweight designed should be.

These are mainly thin stone slabs, which are used in construction, in construction and facade construction, in mechanical engineering and plant construction, or are used in the interior of the home as table tops or kitchen countertops. In particular, thin kitchen worktops are increasingly being used, but also in other areas, such as furniture or fittings construction and construction as stairs, wall coverings and floor tiles, as well as generally used in construction. Stein as a supplier for all kinds of parts, for example when stabilized with carbon fibers, as in the EP 106 92 20 described, have meanwhile found their way into industrial application.

The present invention proposes a way to such thin designed geometries of stone, in particular thin stone slabs or ceramic or artificial stone slabs sustainable as possible cheap way to stabilize them in wide temperature ranges remain stable, that is, that the stone is protected from breakage. Even under mechanical stress to remain so stabilized that the stone protected from breakage is the challenge for the solution described here. The stone slab should get new properties, which one of Stein does not know it so far, because he should be flexible, bendable be without the polished surface is damaged by the bend. The newly created elasticity the plate also provides for a higher one impact strength and for some yielding of the material in the case of impact or shock loading by impulses, as caused by the falling of a pot on a kitchen worktop become.

Thin stone slabs stabilize so that they are as light and flexible as possible and still possible stay straight, should be an essential objective of the present invention be. To achieve this goal, two things are needed. A Feature is that the plate gets a strength that makes it bendable power. The observation shows that slabs, the thinner they are be bendable without breaking. Second, it is necessary that Earthenware or ceramic plates against train and associated Breakage due to overstretching to sustainably stabilize. Therefore It is important that the stone stabilizing the stone after possibility has a smaller coefficient of thermal expansion than the stone to be stabilized.

The Invention proposes One way ahead, the characteristics of bendability and elasticity at the same time To protect against breaking the stone slab so that the Plate remains stable in wide temperature ranges and under pressure on the stone surface while giving in, but only so much that is not the tiniest Violation of the stone surface arises. It is an important goal of the solution described here, specifically the vote of stone strength and to optimize stabilization layer, for example, a thin kitchen worktop to optimize it as possible stable, yet tough at the same time, as well as possible becomes easy.

Of the Here proposed way ensures that both Stone, as well as ceramics among the most diverse thermal conditional mechanical loads, as well as purely mechanical Loads are stabilized so that they through one, for the respective Use and load cases suitable, stabilization against mechanical destruction by tearing the flagstones on the one hand, and especially in addition to mechanical breakage protected be and as possible becomes easy.

core the solution is that for thin stone slabs on the one hand best fitting strength to find - too from a cost point of view, as well as the most suitable stabilizing material to find. It is important, the total expansion coefficient of the Stone stabilizing material on the stone stabilizing Set side between flagstone and stabilizer material so that he is similar or better yet, is still slightly smaller than the total expansion coefficient the stone slab itself.

The invention is based on the use of an approximately 10 mm thick stone plate and the stabilization of this stone plate by a partially or the whole surface mounted on the stone fiber containing carrier material, which has a Ausdehungsverhalten that comes as close as possible to the stone. For this purpose, carbon fibers and / or stone fibers, in particular basalt fibers, are used in the present invention.

The panel thickness of 10 mm is the lower dimension used in modern gate sawmills serrated can be and where the disk is just so stable that she does not break. In this condition, the plate is also very good bendable and elastic, without compromising on handling without stabilization break. By realtiv simple milling it is now possible Stone thickness after gating and one-sided Verklben even thinner too while calibrating with high accuracy. The plate will be there to a size of about 9 mm thickness brought.

Known are previously lightweight designs in which as in this new invention also one possible thin natural stone layer protected with fiber matrix against breakage becomes and areal through an additional Substructure of various substrates and Support shapes, like frames, honeycombs and the like Strengthen constructions and thereby made resilient, or it is only made possible, Stone geometries such as stone slabs or stone rods accordingly thin perform. The support material is usually chosen from the point of view, that it with sufficient mechanical strength mainly from the use of conventional Materials such as steel and aluminum, or such layers determined is that of a similar one or the same material as the material to be stabilized. Newer methods suggest glass fibers, aramid fibers or carbon fibers as a carrier material in front. Each of these fibers has a certain physical advantage, but also specific disadvantages, depending on the application. Suitable from Total spectrum of physical properties seems carbon fiber or to have the stone fiber itself to stabilize stone. The coefficient of expansion, tensile strength and tensile elongation comes closest to the physical properties of the stone. It will be additional For example, straight, corrugated or honeycomb-shaped metal or aluminum sheets, Wooden panels and steel or wooden frames, or other stone slabs as a carrier material used, with the thin ones Stone geometries a strength of up to 15 mm or less, without breaking. Such additional Stabilizing measures are not required in this invention, wherein the characterizing feature basically the stone layer thickness of is about 9 mm and the use of carbon fibers or stone fibers proposed as a stabilizing layer directly on the Stone to be applied to the stone slab to be stabilized flexible and shatterproof at the same time.

The carrier material, referred to below carrier, consists - as in the patent application EP 106 20 92 from a fiber-reinforced matrix, which is a synthetic resin or possibly even a ceramic material. Carbon fibers are used, for example, which withstand high tensile loads and contract under the effect of heat, ie have a negative coefficient of thermal expansion and stabilize a more or less thin flagstone. As a result, the plate is particularly protected against cracks due to overstretching and heat, and counteracted the breakage by mechanical stress perpendicular to the earthenware. In addition, stone fibers can be used because they are also very tensile and have a small coefficient of expansion.

One additional Stabilization process is in combination with carbon fibers and / or stone fibers also the use of glass fiber or aramid fiber laminates to apply together with the carbon fiber or stone or Basalt fiber, the stone more or less large or even on one side stabilize. The result is a pressure and tension loadable Stone geometry, which in normal applications for adequate stabilization of the stone for thermal and mechanical load cases ensures. If the plate serves as a worktop, there is the stabilizing layer below, which rips the pressure or a jolt from the top of the plate intercept or rather literally cushioning what the new quality by this invention means.

In most cases is a sufficient stabilization already with a thin film achieved by carbon fiber material or stone fiber matrix, both a stabilization in the thermal, as well as in the mechanical load case guaranteed.

The Task, the slope of thin Natural stone and / or ceramic plates for breaking or tearing too to safely counteract much lighter designs, is through the stabilizing carrier or the stabilizing carrier materials solved. For this purpose, a carrier material is used, which one similar has low coefficient of expansion, as the too-stabilized Flagstone.

The carrier material, hereinafter referred to as carrier, consists of a fiber-reinforced matrix, which is a synthetic resin or optionally itself a ceramic material. It come as a fiber material carbon fibers, stone fibers, especially basalt fibers are used, which withstand high tensile loads and expand only minimally under heat, so have a very small coefficient of thermal expansion, usually smaller than that of the stone material to be stabilized. As a result, stone slabs are protected, in particular against cracks by overstretching and heat, and counteracted the breakage by mechanical stress perpendicular to the earthenware. In addition, so far plates must - depending on the application - additionally for mechanical stresses - as in EP 106 20 92 described with an additional Snadwicheinlage - made stable. This is no longer necessary in the present invention, since the plate down - if the carrier is under the plate - can bend without the stone breaks. At best, another layer may be used, which consists of a flexible material, for example a rubber-like material, which can additionally dampen bumps.

Thin flagstones, for example, work plates - in particular Kitchen countertops and cladding, be by the invention in particular at the same time thermal and mechanical stress and the associated carrier material strain, which cause cracks or surface fractures of the worn stone material would not only safe against cracking, but in particular impact in the case of impulse action. The usually resulting, in certain circumstances microscopic hairline cracks that lead to the rapid decay of the stone, in particular then, when he's outdoors, or as a countertop in the kitchen area constantly changing temperatures, mechanical pressure loads and water and possibly exposed to frost, are completely excluded by the invention, without having to resort to a massive design and the plate so light, just possible becomes. The total plate including the stabilizing layer can thus extremely lightweight and yet extreme pressure, Take up bending and momentum loads without breaking or hairline cracks to get and still be produced at reasonable cost.

These thin Stone slabs can produced by means of the invention while maintaining sufficient stability which one is used to from massive stone material. Generally this can be newly created flagstone in many areas of steel and aluminum replace. Natural stone has a specific weight equal to that of Aluminum and the compressive strength of a normal structural steel, which means that you stone, especially the natural stone plate, now against Break protected is because it has a smaller expansion coefficient than that Stone itself, especially in lightweight construction can use what represents a novelty in technology and therefore becomes important because stone in boundless masses as cheap material everywhere available to the world stands and very energeischonend won and can be easily broken down.

With Help of the use of, for example, temperature-stable epoxy resins, Polyester resins, resins based on phenolic, polyimide, cyanate, melamine, Polyurethane or silicone base, called matrix, in combination with Carbon fibers or stone fibers that have a smaller coefficient of thermal expansion as a stone, now a secure stabilization of stone slabs, in turn, the stabilization of fiber-structured components as well as stone components can serve themselves, possible.

It gets over it addition to the requirement, the mechanical strength and temperature resistance of thin stone geometries to optimize so that the Total expansion coefficient of a stone slab in wide temperature ranges in the stabilizing layer to the same or similar Value can be adjusted to, among other things, the bowls of thin To avoid stone slabs and still realize a lightweight construction. At the moment where it succeeds in stretching the stabilizing layer made of carbon fiber or stone fiber by introducing a certain bias To keep smaller than the stretching of the stone itself, one becomes on this way stabilized stone rods even within certain limits in the stabilization layer opposite side can bend, without that these break. base for this finding is that made in connection with this invention Observation that, in particular, natural stone is actually non-destructive compresses, So z. B. a stone slab by bending pressure in length at one make polished stone side smaller without the polished one surface takes the least damage.

The Invention is realized by the one-sided partial or full-surface coating a 9 mm flagstone that has a tolerance of minus 1 mm up to plus 0.9 mm, with a carbon fiber or rock fiber laminate, the mixing ratio of fiber and resin can be adjusted so that the coefficient of expansion smaller stone to be stabilized and the rock fiber laminate or at least practically identical. The total strength of Plate remains under 10 mm, with a tolerance of 1/1000 mm. The total carrier layer and their strength can also be through a mixture of different additional Fibers are achieved. The total thickness of the plate is stabilizing layer between 8.9999 mm and 9.9998 mm.

One of the many possible embodiments of the invention describes a 9 mm thick plate of stoneware ( 1 ) unilaterally with a carbon fiber roving ( 2 ) is stabilized ( 1 ). The connection between stone and fiber is z. B. produced by a temperature-stable epoxy resin, which can be thermally stable depending on the field of use and their total coefficient of expansion of fiber and matrix should be similar to that of the stone plate to be stabilized.

2 shows this second embodiment of the invention as a 9 mm stone slab ( 1 ), the teilwesie with a layer of stone fiber matrix ( 2 ) whose coefficient of expansion is less than or equal to or at most only slightly larger than that of the stone slab to be stabilized, which is used as a kitchen worktop with a decorative edge ( 3 ) and excerpts ( 4 ) is provided for sink and hob.

3 shows a special version of the flagstone as a worktop ( 1 ), whose stabilization layer of stone fiber matrix ( 2 ) has the same or at least identical expansion behavior as the flagstone to be stabilized. In addition, a damping rubber layer ( 3 ) is mounted under the carrier.

Claims (12)

Arrangement with a slab of stone, natural stone, stoneware, artificial stone, concrete, ceramics, glass-containing material or glass - hereinafter called stone - which is unilaterally partially or wholly stabilized with a fibrous matrix - hereinafter referred to as support, characterized in that the Thickness of plate and support is at least 8.9999 mm and not more than 9.9998 mm. Arrangement according to claim 1, characterized that the carrier Contains carbon fibers. Arrangement according to claim 1, characterized that the carrier Stone fibers, in particular basalt fibers, contains. 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 Claims 1 to 4, characterized that the carrier a mixture of different additional fiber materials, e.g. Glass fibers or aramid fibers, or is different from meheren consists of these fibrous layers or a mixture of carbon and stone fibers with other fiber materials. Arrangement according to Claims 1 to 6, characterized that matrix and fibers have an overall coefficient of expansion similar to that of the one to be stabilized Have stones. Arrangement according to claims 1 to 6, characterized that the expansion coefficient of the fiber matrix is less than or equal to that of the stone to be stabilized. Arrangement according to claim 1 to 8, characterized that the fiber-stabilized plate as a structural component in construction and mechanical engineering accomplished is. Arrangement according to claim 1 to 9, characterized that the fiber stabilized plate as a worktop, in particular as a kitchen worktop, accomplished is. Arrangement according to any one of claims 1 to 10, characterized in that in the case that ceramic in the manner defined in the claims 1 to 10 manner stabilized, the stone fiber incorporated into the ceramic material is and thus the material to be worn together with the stone fiber itself to the carrier material is so that the material thus obtained, inter alia, a brake pad or becomes a self-stabilizing component. Arrangement according to claim 1 to 10, characterized in that under the carrier part-surface, large area or the whole area a dampening further Layer, in particular a more or less soft plastic, Rubber or rubber-containing material is attached, which depending on the damping needs more or less thick is.