DE202006018610U1 - Stone plate, eg natural stone, is stabilised using a matrix carrier that contains a fibre material, and a layer of wood - 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 fibres are carbon fibres. A layer of wood (3) is located under the fibres for additional stability.

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 possible thin and material-saving, philigran and especially light-weighted should.

These are increasingly thin slabs of stone, 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 be so by a combination of materials be stabilized that it is easy to handle without having to break. The newly created stability of the plate also ensures for one higher impact strength and for some yielding of the material in the case of impact or shock loading through impulses, such as by dropping a pot on a kitchen counter top can be caused.

Thin stone slabs stabilize so that they are as light and flexible as possible and still possible 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 in the wrong direction, that is, the stone side is the knovexe Side is to sustainably stabilize so that convex tungsten aud the stone side is prevented. For that it is important that the the stone stabilizing carrier if possible has a smaller coefficient of thermal expansion than the to be stabilized stone and that under this carrier a additional carrier which prevents the convex bend on the stone side. 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 Injury to the stone surface arises. It is an important goal of the solution described here, specifically the tuning of stone strength, Stabilizing layer and additional stabilizer to optimize so that, for example, a thin kitchen worktop on the one hand thin and can become light and that on the other hand this as stable and insensitive against bending, as it occurs, for example, during transport, becomes.

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 easy and tough.

The core of the solution is to find the most suitable stabilizing material for thin fiber reinforced stone slabs. It is important to set the total expansion coefficient of the stone-stabilizing material on the stone-stabilizing side between flagstone and stabilizing material to be similar or better still slightly smaller than the overall expansion coefficient of the flagstone itself. Additionally, it is indispensable for many applications Protecting the stone slab from bending in the wrong direction, because experience has shown that it has to be transported, installed and fastened whose corpse of such thin flagstones is a problem.

The Invention is based on the use of a more or less strong Slab of stone and the stabilization of this stone slab through a partial or full area mounted on the stone fibrous carrier material, which has a Ausdehungsverhalten has that the stone as possible comes close. Therefore In the present invention carbon fibers and / or Stone fibers, especially basalt fibers used. The plate thickness of 10 For example, mm is a suitable measure that gives lower dimension out of the possibility to mill the stone, for example, to less than 1 mm thickness. By calibrating it is possible the stone thickness after the gate and one-sided Verklben exactly very thin too do.

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 also needed in this invention, wherein the characteristic feature basically the use of carbon fibers or rock fibers is proposed as a stabilizing layer applied directly to the stone to stabilize it To make flagstones flexible and at the same time unbreakable and an additional Edging made of wood, which together with the stone the front edge the stone plate forms.

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. For example, carbon fibers or more recently also stone fibers are used which withstand high tensile loads and even contract under the effect of heat in the case of the carbon fiber, 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, since the stone is compressible without being destroyed. Likewise, stone fibers can be used because they are also very tensile and have a small coefficient of expansion. An additional stabilization method is to apply, in combination with carbon fibers and / or stone fibers, the use of glass fiber or aramid fiber laminates which together with the carbon fiber or stone or basalt fiber stabilize the stone more or less extensively or even over the entire surface on one side. The result is a pressure and tensile load-bearing stone geometry, which ensures in normal applications for a sufficient stabilization of the stone for thermal and mechanical load cases. If the plate serves as a worktop, the train-stabilizing layer is below, which catches the pressure or a shock from above the plate without cracking, or rather cushioning. What has been lacking so far is a visually appealing solution, by preventing the front edge from bending in the other direction, which, for example, when transporting such thin plates, causes the stone side to break by bending in the wrong direction.

In most cases is sufficient stabilization in one direction already with a thin one Film obtained from carbon fiber material or stone fiber matrix, the both a stabilization in the thermal, as well as in the mechanical Load case ensured.

The Task, the slope of thin Natural stone and / or ceramic plates for breaking or tearing at much lighter designs in the other direction safely is counteracted by an additional stabilizing carrier or Stabilizing carrier materials made of wood. For this purpose, a wooden strip is used at the front edge, the one additional mechanical stabilization causes and at the same time as a front Edge of the stone plate is used.

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. Carbon fibers, stone fibers, in particular basalt fibers, which withstand high tensile loads and expand only minimally under the action of heat, ie have a very small coefficient of thermal expansion, which is generally smaller than that of the stone material to be stabilized, are used as fiber material. 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 sadwich insert - made stable. This is solved in the present invention by a circumferential wooden strip.

Thin flagstones, for example, work plates - in particular Kitchen worktop and facade cladding or applications in furniture construction, 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 lead worn stone material would, not only safely protected against cracking, but in particular impact in the case of impulse action. The front wooden bar provides also for that, that such wood-reinforced Stone plots easily with other materials, for example furniture Easily connect wood by simply gluing with wood glue.

These thin, With wood stabilized stone slabs can with the help of the invention while maintaining sufficient stability to be produced used to massive stone material is, but are easier and can be very easily connect with other Korpen of all kinds. Generally, this newly created stone slab replace steel and aluminum in many areas, for example as Covering the side walls of computer cabinets. Nature Stone has a specific weight equal to aluminum and compressive strength from a normal structural steel, which means that you stone, in particular the natural stone slab, which is now protected against breakage, because it has a smaller expansion coefficient than the stone itself, especially in lightweight construction, which is a novelty represents in technology and therefore becomes important because stone in limitless masses is available as cheap material anywhere in the world 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. Only the bend in the other direction must be prevented. base for this finding is that made in connection with this invention Observation that in particular natural stone actually compress nondestructive leaves, So z. B. a stone slab by bending pressure in length at one polished stone side can be made smaller, without the polished surface of the least damage takes.

The Invention is realized by the one-sided partial or full-surface coating a, for example, mm thick flagstone with a carbon fiber or rock fiber laminate, wherein the mixing ratio of fiber and resin so can be adjusted that the coefficients of expansion of stabilizing stone and rock fiber laminate smaller or at least are virtually identical. The entire plate is made by attaching a strip of wood additionally stabilized at the edges from below, thereby the bending of the plate in the wrong direction is prevented. The introduction of an entire surface attached wood panel is only advisable in exceptional cases, as a large area attached Wooden plate a bowl can cause the plate at changing temperatures. That depends too from the choice of Holtsorte.

One of the many possible embodiments of the invention describes a 10 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. by a tempera turstabile epoxy resin matrix prepared, which can be thermally stable depending on the field of application and their total coefficient of expansion of fiber and matrix should be similar to that of the stone plate to be stabilized. This fiber reinforced panel is finished with a wooden strip at the front and rear edges ( 3 ) protected against bending.

2 shows this second embodiment of the invention as a 10 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 ) made of wood and cutouts ( 4 ) is provided for sink and hob.

3 shows a special version of the flagstone as a worktop ( 1 ), whose carrier 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 peripheral edge of wood ( 3 ) is mounted under the fibrous matrix carrier.

Claims (12)

Arrangement with a slab of stone, natural stone, stoneware, artificial stone, concrete, ceramic, glass-containing material or glass - hereinafter referred to as stone - which is unilaterally partially or wholly stabilized with a fibrous matrix - hereinafter referred to as carrier, characterized in that Plate under the fiber layer is stabilized with an additional strip or a layer of wood. 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 and wood stabilized plate as a structural component under construction and mechanical engineering is. Arrangement according to claim 1 to 9, characterized that the stabilized with fibers and wood 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 the Wooden strip one at the edge of the plate partially or completely encircling Edge forms. Arrangement according to claim 1 to 10, characterized in that under the carrier where, where he is not stabilized with wood, part of the area, large area or the whole area a steaming another 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.