Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28D—WORKING STONE OR STONE-LIKE MATERIALS
  • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
  • B28D1/005—Cutting sheet laminae in planes between faces
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
  • E04F13/147—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer imitating natural stone, brick work or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass

Definitions

• the invention relates to a multi-layer molded body which carries a superficially visible thin natural stone layer which is connected to a base and / or mold carrier on its flat side facing away from the visible side.
• the invention also relates to a method for producing such a multi-layer molded body which has a thin natural stone layer which is visible on the surface.
• a method for coating furniture, walls, floors, components, car dashboards or the like with a thin layer of natural stone is already known.
• a thin layer of natural stone is applied to a carrier plate to be coated.
• the previously known method provides that the carrier plate, before it is connected to the thin natural stone layer, and the bonded surface of the thin natural stone layer successive application of an adhesion promoter and an adhesive bridge, preferably in the form of a glass fiber fabric or non-combustible fleece, are pretreated, and then, after arranging an adhesive between the opposing adhesive bridges, a non-positive connection of the surfaces of the natural stone layer and the carrier plate to be connected by pressing in the low pressure process under the influence of heat at a temperature of 30 ° to 80 °.
• the solution to this problem according to the invention consists, in particular, in the case of the multi-layer molded body of the type mentioned at the beginning, in that the base or mold carrier is colored and / or that a color layer is provided between the base or mold carrier on the one hand and the natural stone layer on the other hand, and that this is provided by the natural stone layer translucent color or color layer characterizes the visible color of the molded body.
• the molded body according to the invention has a superficially visible natural stone layer. Because between this natural stone layer on the one hand and the base or form support on the other hand one by
• a translucent color layer is provided for the natural stone layer, or because the natural stone layer is applied to a colored base or mold carrier, the color of which also shines through the natural stone layer, a more transparent one or little color-intensive impression of this natural stone decorative layer avoided. Since the color or layer of color which is translucent through the natural stone layer rather shapes the visible color of the molding, this natural stone layer can have a high decorative effect without impairing its natural appearance.
• the base body is flexible and in particular is designed as a fleece.
• Such a resilient basic body which carries the natural stone layer on its visible side, can easily be adapted to the almost any three-dimensional shape of a mold carrier connected to the basic carrier on its side facing away from the visible side.
• the base and / or the mold carrier consists of a thermoplastic material is particularly advantageous.
• a mold carrier consisting of a thermoplastic material can be brought into a defined plastic or three-dimensional shape together with the natural stone layer connected to it directly or via the base carrier under the action of heat.
• At least one transparent cover layer is applied to the natural stone layer, which gives the shaped body a homogeneous smooth and possibly also glossy surface despite the dissolved grain structure of the natural stone layer.
• a natural stone slab is separated from an untreated natural stone block as a slab.
• Natural stone rough blocks in all common sizes can be sawn practically completely in natural stone panels without having to cut them into smaller blocks or fear a high waste.
• the natural stone tablets separated from the raw stone block will then be
• the natural stone panel is connected on at least one flat side to a base or mold carrier, which between this at least one flat side of the
• Natural stone tablet and the adjacent processing support is provided.
• This base or form carrier itself has a sufficiently smooth and dense surface in comparison to the natural stone tablet to create a correspondingly strong vacuum on it To be able to create basic or form carriers. Since the natural stone board is fixed to at least one of the adjacent processing supports by means of a vacuum and since the side of the natural stone board facing away from the visible side is sealed off by the base or mold support, undesired penetration of adhesive or other substances by possible cracks in the natural stone layer is avoided where such substances could lead to an undesirable change in color and thus to an impairment of the natural appearance.
• the composite each consisting of a natural stone sheet fixed between two processing supports, is separated in a parting plane in the area of the natural stone sheet into two processing supports, each connected to a natural stone layer.
• the natural stone layer which can be detached from the processing support, is connected to the base or form support, the natural grain structure of the possibly granular granite or similar stone material can be loosened without the natural stone layer being lost.
• plate-shaped moldings can be produced to a large extent, which, for example, can be attached to a building wall on the outside or inside as comparatively light components.
• plastic or three-dimensional shaped bodies such as, for example, a surface-contoured one, can also be used Car dashboard, have it made.
• the mold carrier consists of a thermoplastic material and that the mold carrier with the natural stone layer, possibly connected to it via a base carrier, is deformed under heat into a defined plastic or three-dimensional shape.
• a preferred procedure according to the invention provides that the natural grain structure of the natural stone layer produced from a granular natural stone is dissolved mechanically or by ultrasound before or during the deformation of the base or mold carrier.
• the base support connected to the natural stone layer consists of a resilient material and is in particular designed as a fleece.
• the natural stone layer can either be permanently connected to such a base support or directly to a shaping support.
• Another procedure according to the invention provides that the natural stone layer on its flat side facing away from the base carrier is inseparably connected to a shaping mold carrier and that the base carrier is detached from the natural stone layer after connecting the natural stone layer and the mold carrier.
• the base support is only used temporarily during manufacture as a fixative or fleece for the thin, sensitive natural stone layer.
• the sensitive natural stone layer which may be rough on the surface after loosening the natural grain structure and adapting to the desired shape of the shaped body, with a protective and / or leveling plastic or lacquer layer, it can be advantageous if at least one layer is applied to the natural stone layer transparent top layer is applied.
• the natural stone panel which is initially only fixed to one of the processing supports, is cut into smaller natural stone panel blanks and if the other is fixed after placing another processing support from the processing supports and the ones in between Natural stone panel blanks formed composite is separated in a parting plane in the area of natural stone panel blanks. While this procedure provides for the natural stone sheet to be cut to size before the composite formed with the fastening supports is separated, the natural stone layer attached to a processing support can also be cut into smaller natural stone layer cuts at a later time, namely after the composite formed between the fastening supports and the natural stone sheet has been separated be tailored.
• Figures la to 12a show the individual process steps that are used to produce a multi-layer molded body with a visible thin natural stone layer.
• a raw stone block 1 is cut on a saw frame 2 into several natural stone panels, which can have a thickness of 15 mm or less. All common sizes can be used practically without residue for the raw stone blocks, without having to divide the raw stone blocks into smaller blocks or fear excessive blending.
• each base support 4 is then connected to a base support 4.
• an adhesive layer 5 is provided between each base support 4 and the natural stone panel 3, which is preferably formed from a two-component adhesive.
• the base carrier 4 consist of a resilient material and are made here from a fleece.
• a plate-shaped processing carrier 6 is now attached to both sides of the natural stone board 3.
• the natural stone board 3 is fixed between the processing supports 6 by means of a vacuum.
• the base support 4 provided between the natural stone board 3 and the respective processing support 6 is prepared or designed in such a way that it has a comparatively smooth and dense surface compared to the natural stone board itself.
• a base carrier 4 designed as a fleece can also be prepared, for example, on its flat side facing away from the natural stone panel 3 with a smoothing and sealing adhesive layer or similar top layer 7. Guides can be provided on the back of the processing supports 6 attached for reinforcement, which are used in subsequent sawing and calibration processes.
• FIG 4a it is indicated that afterwards an announcement takes place by means of diamond wire saws.
• These diamond wire saws can have multiple assemblies, whereby the saw wires can have a diameter of, for example, 8 to 11 mm.
• By sawing the natural stone panels 3, large mirror veneers can be obtained, which are preferred for all marbled stones in the design area.
• FIG. 5 a shows, the processing supports 6 now come on an automatic grinding machine 9, in which the natural stone layer 8 fixed on the processing supports 6 can be brought to the desired final gauge dimension of preferably less than 1 mm.
• the processing carrier 6 can be separated from the base support 4 and the natural stone layer 8 connected to the base support 4 by releasing the vacuum.
• the composite consisting of the base support 4 and the natural stone layer 8 is cut and sawn in an optically controlled stone saw 10 in the process step shown in FIG. 7a.
• Figure 8a it is shown that the blanks consisting of the base support 4 and the associated natural stone layer 8 are processed by ultrasound or mechanically, for example by ball elements or roller application, in such a way that the natural grain structure of the granular natural stone material can loosen and loosen without the overall structure of the natural stone layer 8 is impaired.
• the heating of the composite material formed from the thermoplastic base carrier 4, the adhesive layer 5 and the natural stone layer 8 makes it pliable and is placed on a shaping carrier 11 with the now flexible stone veneer 8. Due to the heating, the dead weight of the composite material and by pressing on a soft, flexible stamp 12 which lies superficially around the mold carrier 11 and which, for example, can have a foam rubber layer with studded strips for later recesses, the composite material produced is preformed and in the same way into the final one Form shape of the molded body pressed.
• the required holding devices can also be back-injected in a subsequent process step.
• the flexible base support 4 which here consists of a fleece, serves to fix the natural stone layer 8 during the processing operations. Since the desired adhesive is applied to the mold carrier 11 before the base carrier 4 is placed on it a possibly also colored base support can contribute to the simultaneous deepening of the color of the natural stone layer 8 by coloring. In order to give the natural stone layer a color-intensive impression, despite its small thickness, without destroying the natural appearance of this natural stone layer 8, in addition to or instead of coloring the base support 4, the natural stone panel 3 shown in FIG. 2a is provided before the adhesive layer 5 and to be provided with a color layer, not shown here, before connecting the natural stone panel 3 to the base support 4.
• FIG. 11 a shows how a transparent plastic or lacquer layer is applied to the natural stone layer 8 of the molded body.
• the cutouts required for attaching switches and the like are then milled out into the shaped body and the edges of the shaped body are trimmed clean, for which purpose a five-fold robot 13 is used.
• the natural stone layer 8 can also be connected to a base support 4 made of thermoplastic material.
• the composite material formed from the natural stone layer 8 and the base support 4 can be deformed in warm bar form can be deformed over a positive mold, which specifies the shape of the later molded body.
• the positive mold is retracted.
• the preformed part consisting of the possibly colored base carrier 4, the adhesive layer 5 and the possibly color-coated natural stone layer 8 is inserted into a negative mold 14, the mold half of which is acted upon by the natural stone layer 8 and is cast with transparent plastic 15 has been.
• FIG. 2b the rear view of the molded body is injected with the holding devices that may be required in a counter mold 16.
• the molded body must also be processed on its edges with the aid of the five-axis robot 13 and provided with the necessary recesses even after these alternative method steps.
• FIGS. 1c to 10c show an alternative method to FIGS. 1a to 12a.
• a raw stone block 1 is also cut on a saw frame 2 in natural stone panels 3 in this method.
• the natural stone panels 3 are then - as shown in Figure 2 - pre-calibrated and ground to the desired grain size.
• the natural stone tablet 3 is, for example, with a Tailored water jet.
• a plurality of composites formed from a natural stone sheet 3 each fixed between two processing supports 6 can also be separated simultaneously in the diamond wire saw.
• the natural stone veneer is brought to the desired final gauge, which can be less than 1 mm, for example.
• FIG. 8c shows the application of the basic carrier 4, which has been brought to the same dimension, remains or is omitted again.
• This base support 4 can also be colored if necessary in order to additionally emboss the color of the later molded body.
• the processing carrier 6 is separated from the blanks, which each consist of the natural stone layer blank 8 and the basic carrier blank 4, which have been brought to the same dimension.
• the natural grain structure of the natural stone material is then loosened and loosened in the method step shown in FIG. 10c in a mechanical manner, for example by application of spherical elements, roller application or by ultrasound processing, without impairing the overall structure of the natural stone layers 8.
• the composite blank formed from the base carrier 4 and the natural stone layer 8 is deformed in the heated state, connected to a shaping mold carrier or with the aid of a molding tool deformed and provided with a protective cover layer made of transparent plastic or varnish in order to be able to mill out the necessary recesses and trim the edges.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Mining & Mineral Resources (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)
• Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Floor Finish (AREA)

Applications Claiming Priority (3)

Publications (2)

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ID=7906928

Family Applications (1)

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Cited By (1)

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Family Cites Families (8)

• 1999
  • 1999-05-05 DE DE19920492A patent/DE19920492A1/de not_active Ceased
• 2000
  • 2000-02-29 DE DE50014118T patent/DE50014118D1/de not_active Expired - Lifetime
  • 2000-02-29 EP EP00909272A patent/EP1175540B1/fr not_active Expired - Lifetime
  • 2000-02-29 AU AU31616/00A patent/AU3161600A/en not_active Abandoned
  • 2000-02-29 ES ES00909272T patent/ES2282094T3/es not_active Expired - Lifetime
  • 2000-02-29 AT AT00909272T patent/ATE355429T1/de active
  • 2000-02-29 WO PCT/EP2000/001698 patent/WO2000068530A1/fr active IP Right Grant

Non-Patent Citations (1)

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