DE3940102C2 - Process for coating with thin layers of natural stone - Google Patents

Description

The invention relates to a method for coating furniture, Walls, floors, building elements, building boards and building materials with thin natural stone layers, and the use of coating produced by the process and objects.

Natural stone is due to its architectural impact, as well as its Durability in shape and color is one of the highest quality and most sought after Architectural materials. Are known thin layers of stone on assembly establish any type with ver relative to an applied stone layer different responsiveness to physical loads, it is desirable, a permanent weather, gate in every application To ensure sions- and / or vibration-resistant material composite, so Be Layers with thin layers of stone risk-free a wide use area can be made usable.

From DE-GM 18 90 769 floor panels are composed of a tra known base plate and an outer plate made of natural stone. To the surface The visible surface of the stone slab is treated on a sub-slab bonded state ground. Composite panels, which is a natural stone Layer and have a reinforcing support plate are in a similar Aus education also known from DE-OS 21 29 057 and DE-OS 37 09 224. All Such known composite panels each have natural stone layers as Visible surfaces, as well as carrier plates in multiple thicknesses of the natural stone layer which, when used as a veneer for installation reasons, additional Reinforcement, reinforcement or protective layers between the installation base and Represent stone layer.

For the production of thin stone layers on reinforcing carrier plates you go the technically complex way, thick stone slabs first of all on one or both sides with tensile and compression reinforcement layers ten to then provide a central separation cut through such a witnessed to perform sandwich plate. Such composite panels are as a pro products of EP 19.419 A1, DE 28 33 874 A1 and EP 252.434 A2 to take. The processes of this type have in common that surface treatments the visible surfaces by sanding, polishing and sealing only after the separation operations take place, at this stage the reinforcement or protection layers particularly resistant to swelling in the stone industry  must be wet surface treatments.

Finished natural stone surfaces can be treated with a trans Parent further coating, such as glass, as in the EP 122.357 A1. A load on the laminate is admittedly Avoid swelling, but there is a considerable increase in weight tion and consequently a limitation of the areas of application of such Ver fret plates.

In a manufacturing process known from GB 2,163,094 A. only small-format natural stone slabs under a cutting process pulled, because here lower vibrations than when cutting from large origin plates arise, so that measures to increase stability, such as the application of reinforcement layers. As a result of technical coping from only small plate formats, the areas of application are to use known tiles and tiles limited.

Furthermore, several processes and plants for the production of thin, Stone slabs are known, in which a surface is at least one-sided treated original plate, or an original block, without ar reinforcing layers with a stabilizing workpiece fuse, sawn into predeterminable thin plates, so that thin Stone layers of any format for further use acts and is available independently. In the usability of thin layers of stone as visible surfaces it represents a significant qualitative improvement if these in the same way as classic veneers without additional reinforcement layers constantly, as well as already surface-finished for visible surface design any assembly reasons can be used.

From DE-GM 71 19 037 are self-adhesive under the action of heat Hot melt adhesive is known as an adhesion promoter film, but it is permanent Composite only with installation reasons with the visible Be allow stratification of comparable physical reactivity, so that esp especially a combination with assembly reasons from organic or slightly swell material can only withstand low loads.

The use and processing of veneers is from the wood industry known, which you can glue directly onto an assembly base, or construction panels veneered on one or more sides for further use poses.

The invention is therefore based on the object of a method type mentioned in favor of an expansion of the areas of use known thin stone layers to improve, in particular the manufacture Permanently non-positive weather, torsion and / or vibration resistant  Association between stone layers and installation reasons of any kind essential Lich is simplified, and he improved phase transitions at the adhesive joint aims to be.

This object is achieved according to the invention in a generic method solved in that first an assembly reason to be coated, before he with a thin layer of stone is connected, as well as the composite surface of a thin Stone layer, in each case by successively applying an adhesive medium and an adhesive bridge, preferably in the form of a glass fiber fabric or non-combustible fleece, are pretreated, and then, as directed of an adhesive between the opposing adhesive bridges non-positive connection of the surfaces to be connected by pressing in Low pressure process under the influence of heat at a temperature of 30 to 80 Grade C is done. Depending on the specific material substance, an adhesion promoter is used of the mounting reason to be coated, a corresponding film-forming two Component binder used, which by the action of heat Polyaddition or polymerization crosslinked. Such chain-like or ver wetting molecules are characterized by high resistance to changing Environmental influences. Other ways to use it as an adhesion promoter offer a solvent-free two-component polyurethane adhesive heat-resistant polychloroprene, or a copolymeric vinyl acetate, the isocyanate is mixed as a hardener, the alcohol and isocyanate types so can be chosen that after curing, depending on the application of Coating, a hard, medium-hard or permanently elastic film layer on the forms areas to be connected. An adhesive bridge in the form of a glass fiber ge webes is launched after the adhesion promoter has been briefly vented. As an adhesive bridge polyacrylate or resorcinol resin are also suitable. As a glue it becomes difficult flammable epoxy, polyurethane, polyester or acrylic resin used.

This procedure is simple and regularly enables a permanent one Association between surfaces to be connected of different physical reactions bility, which loads in the most extreme areas of use holds. With regard to temperature change, torsion and vibration responsiveness - with wood, for example, as a mounting base to be coated and one to open Bringing stone layer as a visible surface - are by shifting the physi Kalische phase boundaries of different laminates on their bonding improved phase transitions, as well as dimensionally stable bond on one preferably permanently elastic adhesive joint achieved. Preferably the Phase boundaries between the installation reason to be coated and a stone layer so moved that after arranging glue and laying on a ver Stone layer pretreated according to the driving method onto a layer to be coated  the reason for the assembly was the adhesive forces of the adhesive bridge to the stone layer on the one hand, and the adhesive bridge on the assembly base to be coated on the other come fully into effect. During pressing in the low pressure process the laminates are mutually anchored under the influence of heat by polymerizing the adhesive both in the adhesive bridge of the assembly basic, as well as in the adhesive layer of the stone layer, as well as a merger of the layer structure to a physically largely homogeneously reactive dimension composite.

As we in extreme temperature change simulation, as well as and have determined torsion attempts result from the procedure appropriate construction of the adhesive joint immediate physical advantages, such as high thermal resistance and strong adhesive strength. As more before partial property was a special resistance of the coating against dynamic influences. With the help of known stone Machining tools can drill holes, millings and Inlays can be carried out without the risk of splintering and breaking.

According to one embodiment of the method, opposing ones Sides of a building board each coated such that arranged stone layer protrude beyond at least one edge of the building board, and generated in such a way te channel-shaped column in an analog composite process decorative laminates used and pressed together with the cover-side coatings.

Preferred uses are in the process according to the invention provided coatings for the production of visible surface-finished construction elements and building materials, such as from an extremely robust view surface coatings on well-known dry screed plates or thin beds elements for flooring. Especially when processing dry screed With the coating according to the invention, plates can be fine in one operation screed and decorative, heavy-duty stone covering designed on coarse concrete become. In an analogous manner, building materials of any kind can be used in building guide including decorative, resistant visible surface coatings in be processed in one operation.

With preferential production of visible stone coatings The optical exists on all broad and narrow sides of a building board Effect of a massive stone slab. Coated on at least one side Building boards find preferred use as structural components in Architecture and furniture making.

With preferred use of the coating according to the process provide visible surfaces on door frames, door leaves, frames and vehicle and ship cockpits prove their vibration and torsion resistance, as well as their moisture resistance as particularly advantageous and open up  further problem-free areas of application of known thin stone layers.

Further advantages and details of the invention emerge from the the following description of the exemplary embodiments with reference to the drawings.

Show it

Fig. 1 is a block diagram of embodiments of the method;

Figure 2 is a schematic representation of the structure of a procedural stone coating in cross section.

Fig. 3 is a furniture coating, and use completely encased structural panels, in perspective view;

Figure 4 shows a coating structure using the example of a door frame, in perspective view.

FIG. 5 shows a method according coated Fahrzeugarmaturenpaneel, in front view;

Figure 6 is a procedural all-round coating of a construction plate, in a perspective view.

Fig. 7 is a method according coated bottom facing plate, in cross section;

Fig. 8 is a multi-part prefabricated element to the bottom clothing, in perspective view;

Figure 9 is a stone both sides coated plate with profiles on their narrow sides, in a perspective view.

Fig. 10 is a one-sided coated building board with inlay, in a perspective view.

The block diagram in FIG. 1 shows the sequence of the process steps according to the invention using the examples of coating a prefabricated piece of furniture in process route A and a complete all-round sheathing on a wooden plate for use as a load-bearing furniture component in process route B.

The coating method according to the invention is explained in more detail with reference to FIGS . 1 and 2: an assembly reason to be coated - 2 - before it is connected to a stone layer, and the bonded surface of an independent, surface-treated stone layer - 1 - that is less than 7 mm thick, are each represented by successive order of an adhesion promoter matched to the assembly to be coated - 3; 4 -, and an adhesive bridge - 6 - pretreated in the form of a preferably permanently elastic curing glass fiber fabric or non-flammable fleece. After arranging an adhesive - 5 - between the opposing adhesive bridges - 3, 4 - the layer structure - 1, 3, 6; 5, 6, 4, 2 - pressed in the low pressure process under the influence of heat at a temperature of 30 to 80 degrees C and a non-positive connection of the surfaces to be connected - 1, 2 - produced. To be coated assembly reasons - 2 - correspond in process path A to the visible surfaces of a prefabricated piece of furniture, as shown in FIGS . 3 and 4. Thin stone layers - 1 - are preferably prefabricated in appropriate template sizes. Is, as shown in Figure 6 in greater detail - in the process path B all the wide and narrow sides correspond to a wood plate - 100 - to be coated assembly reasons -. 2. Materials that swell, particularly when exposed to moisture, such as wood, experience a permanent seal due to the coating according to the invention, which opens up wider areas of application for such building panels.

Fig. 3 shows a piece of furniture, manufactured using the cumulative use of the process routes A and B according to FIG. 1. The side walls - 21 -, bottom and cover plate - 22, 30 -, shelves - 49 -, and door leaves - 23 - are according to Method B of Figure 1 from all-encased wooden panels - 100 -; Fig. 6- made. Further, approximately profiled surface sections - 2, 18, 19 - which are still to be coated are, after analogous pretreatment, coated with thin pretreated stone layers - 13, 6 - in accordance with process route A of FIG . The graphical enlargement window shows the structure of an all-round coating according to the method, as has already been described for FIGS. 1 and 6.

Fig. 4 illustrates the layer structure of a method Be coating based on the example of a made of wood, plastic, concrete, or Metallpro filen - 40 - prefabricated door frame. The layer structure of the adhesive joint speaks accordingly to that shown in FIG. 2. The preconditioned stone layers - 13 - required for coating are cut according to the surface to be coated - 14 -. With full-surface coating of the frame, the optical effect of massive marble profiles is created.

In Fig. 5, a car fitting panel with a process-based stone coating, as well as with milled cutouts - 29 - and holes - 28 - is provided. Individual sections preferably have inlays - 26 - through decorative metal, wood, plastic or natural stone inlays - 10, 11 -.

Fig. 7 shows sichtflächenendgestaltete bottom facing panels - 46 - which in each case a thin, exposed surface pretreated stone coating - 13 -, as well as gypsum and polystyrene plates - 2, 9 - having as an insulating layer for the insulation of moisture, heat and / or sound. As a result of this arrangement, fine screed - 24 - and surface-treated decorative visible surface - 1 - are laid as modular components directly on roughly toned floor - 50 .

FIG. 8 shows the use of coatings according to the method on transportable, multi-part thin-bed elements 45 for floor covering, with star-shaped inlays 26 in this exemplary embodiment. Depending on the area of application, a coating with a thin stone layer - 1 - can also be applied to wood, dry screed, aerated concrete or metal-reinforced installation reasons - 2 -. To adapt to any uneven installation reasons - 2 - in this example, the lowest layer - 9 - of the thin-bed element - 45 - is preferably made of soft-elastic material, in particular polystyrene.

Fig. 9 shows a construction variant of the coating according to the method, profiles - 15 - on the narrow sides of a pretreated stone layer - 13 - coated pretreated building board - 100 - are provided. This requires that stone coatings - 13, 13 ' -, which are applied to ge opposite surfaces - 2 - a building board - 100 - protrude on one edge. This creates a channel-shaped column on a narrow side of the building board - 100 -, in which decorative laminates - 10, 11, 12 - of any materials are inserted in a composite process analogous to the surface coating. The profiles - 15 - are pressed together with the rest of the coating.

Fig. 10 shows the production of inlays - 26 - with any insert materials - 27 - using the coating method according to the invention. As a result of the favorable cohesive forces, as well as the high vibration and torsional strength of the coating, there is an almost risk-free option for any bores and millings - 25 - in the coating using known stone-working tools.

The present invention is based on the embodiments that only are shown for example, not limited, but excludes changes and generalizations as they result from the claims.

Claims (7)

1. A method for producing composite panels for furniture, walls, floors, components, building boards and building materials with thin natural stone layers, characterized in that first a support plate to be coated ( 2 ) before it is connected to the thin natural stone layer ( 1 ), and the Composite surface of the thin natural stone layer ( 1 ), in each case by successively applying an adhesion promoter ( 3 ; 4 ) and an adhesive bridge ( 6 ), preferably in the form of a glass fiber fabric or non-combustible fleece, pretreated, and then, after arranging an adhesive ( 5 ) between the opposing adhesive bridges ( 3 , 4 ), a non-positive connection of the surfaces of the natural stone layer ( 1 ) and the support plate ( 2 ) to be connected by means of pressing in the low pressure process under the action of heat at a temperature of 30 to 80 degrees C. 2. The method according to claim 1, characterized in that a film-forming two-component binder is used as an adhesion promoter ( 3 ; 4 ), which crosslinks under the action of heat by polymerization. 3. Process according to claims 1 and 2, characterized in that a flame-retardant epoxy, polyurethane, polyester or acrylic resin is used as the adhesive ( 5 ). 4. Use of coatings produced by the method according to one of claims 1 to 3 ago for producing intarsations ( 26 ). 5. Use of coatings produced by the method according to one of claims 1 to 3 for the production of visible surfaces ( 1 ) on known dry screed plates ( 24 ) and on known thin-bed elements ( 45 ) for floor covering. 6. Use of coatings produced by the method according to one of claims 1 to 3 for the production of visible surfaces ( 1 ) on door frames ( 40 ), door leaves ( 23 ), frames, vehicle and ship cockpits. 7. Use of building panels ( 100 ) coated on at least one side by the method according to one of claims 1 to 3 as structurally load-bearing components in architecture and furniture construction.