FR2937345A1 - Decorative slab for use on e.g. block, has stoneware based upper decorative layer fixed on concrete lower support layer, where lower support layer is realized by hydraulic cement based construction material - Google Patents

Abstract

The slab (10) has a stoneware based upper decorative layer (11) fixed on a concrete lower support layer (12) by latex based adhesive intermediate layer. The lower support layer is realized by hydraulic cement based construction material, where the hydraulic cement has quartz based adhesive cement. The adhesive intermediate layer is arranged between the upper decorative layer and the support layer. Rigid reinforcement is downed in the support layer. An independent claim is also included for a method for fabricating a decorative slab.

Description

DECORATIVE TECHNICAL TILES TO BE POSITIONED ON PLOTS OR BED OF SAND.

Description Technical Field of the Invention

The present invention relates to decorative technical slabs intended to be placed on studs or on a sand bed. It also relates to a method of manufacturing decorative technical slabs.

In general, the invention relates to the technical field of the building and more particularly that of the realization of terraces or swimming pools.

State of the art We know the slabs for the manufacture of terrace to be placed on studs or on a bed of sand. These slabs can have different shapes, different dimensions and be made of different materials. Among others, we know the concrete slabs that can be in the form of a concrete slab (1) smooth as that shown in Figure 1.a) or a concrete slab (1) covered with a layer of gravel ( 2) like that 2937345 -2

shown in Figure 1.b). These concrete slabs have the main disadvantage of being very heavy and therefore difficult to manipulate during installation.

Referring to Figure 2), wooden slabs 5 (3) are also known. These wood slabs (3) have the advantage of being light, but are difficult to maintain. In addition, wooden slabs become very slippery in the presence of water. Their use is therefore not recommended in damp places and especially near the pools.

Full-body porcelain stoneware tiles (4) as shown schematically in FIG. 3) can also be used. However, this type of slab is quite fragile and can only be made in small dimensions, for example for a porcelain stoneware tile (4) of square shape the maximum dimensions are about thirty centimeters side. In addition, because of their reduced dimensions, it will be necessary to use many more blocks for the realization of a terrace from porcelain-stone slabs (4) than for the realization of a terrace from slabs concrete (1) or wood slabs (3).

Referring to Figure 4), we still know the tiles-porcelain so-called duo. These slabs are in the form of two porcelain stone slabs (4,4 ') full masses bonded to one another by means of an adhesive or glue (5). These slabs are then reversible offering on each of their faces a different pattern. However, sheer problems were observed on the duo porcelain tiles. In addition, they behave badly in outdoor environments subject to freezing and thawing.

Synthetic slabs (6) as shown in FIG. 5) can also be used, which are made of resin. The major disadvantage of synthetic tiles (6) is that they are very slippery. 2937345 -3

The main object of the present invention is to provide a decorative technical slab intended to be placed on studs or on a bed of sand which is light, non-slip, of small thickness resistant to external conditions, of easy maintenance and variable patterns. Yet another object of the invention is to provide a quick and easy manufacturing method of this decorative technical slab object of the invention.

Yet another object of the invention is to provide a decorative technical slab of simple and inexpensive design.

Disclosure of the invention. The solution proposed by the invention is a decorative technical slab intended to be placed on studs or on a bed of sand remarkable in that it comprises: - an upper decorative layer based on porcelain stoneware, 20 - a lower support layer made by a building material based on hydraulic binder and on which is fixed said decorative layer. The top decorative layer in porcelain stoneware makes it possible to obtain a slab of tiled appearance with variable motive, non-slip and easily cleanable. The presence of a support layer makes it possible to minimize the thickness of the decorative layer. The choice of a building material based on hydraulic binder for producing the support layer allows the manufacture of slabs of different sizes and in particular large, light and thin. According to an advantageous characteristic of the invention making it possible to obtain a support layer having good mechanical characteristics (resistance to compression, to bending, etc.), the support layer is made of reconstituted stone. According to another advantageous feature of the invention for improving the fixing of the decorative layer on the reconstituted stone support layer, the hydraulic binder comprises a quartz-based adhesive-cement.

According to yet another advantageous feature of the invention for improving the mechanical characteristics of the support layer, fiberglass is mixed with the hydraulic binder.

According to yet another advantageous characteristic of the invention making it possible to improve the fixing of the decorative layer on the reconstituted stone support layer, the decorative layer is fixed on the support layer by means of an intermediate layer of glue. latex base disposed between said decorative layer and said support layer.

According to yet another advantageous characteristic of the invention making it possible to obtain a support layer having good mechanical characteristics (resistance to compression, to bending, etc.), the hydraulic binder of the support layer is of adhesive cement.

According to yet another advantageous characteristic of the invention making it possible to obtain a support layer having good mechanical characteristics (compressive strength, flexural strength, etc.), the support layer is made of concrete.

According to yet another advantageous characteristic of the invention making it possible to improve the mechanical characteristics of the support layer, a rigid reinforcement is embedded in the lower support layer.

Another aspect of the invention relates to a method of manufacturing the slab which is the subject of the invention in which: - a decorative layer consisting of a porcelain-based plate is placed in the bottom of a mold; pouring a support layer of hydraulic binder based construction material on the decorative layer, - the slab is demolded after hardening of the support layer.

The molding process makes it possible to quickly obtain slabs of regular shape and thickness.

According to yet another advantageous characteristic of the invention, asperities are formed on the upper surface of the decorative layer before casting of the support layer. The creation of asperity on the upper surface of the decorative layer allows better attachment of the support layer subsequently cast on this face.

According to yet another advantageous characteristic of the invention making it possible to homogenize the support layer in order to guarantee the best possible mechanical properties, the support layer is cast-vibrated on the decorative layer. According to yet another advantageous characteristic of the invention making it possible to optimize the fixing of the decorative layer on the support layer, an intermediate layer of latex-based glue is cast on the decorative layer before casting of the support layer.

According to yet another advantageous feature of the invention for increasing the mechanical properties of the support layer, there is a reinforcement in the mold on the decorative layer, before casting of the support layer.

According to yet another advantageous feature of the invention facilitating the demolding of the slabs, using a silicone mold. Description of the figures.

Other advantages and characteristics of the invention will appear better on reading the description of a preferred embodiment which follows, with reference to the appended drawings, carried out as indicative and non-limiting examples and in which: FIG. 1.a) schematically represents a smooth concrete slab of the prior art; FIG. 1.b) schematically represents a concrete slab covered with gravel of the prior art; FIG. 2) schematically represents a slab; wood of the prior art, - Figure 3) schematically shows a sandstone-porcelain slab of the prior art, 15 - 7

FIG. 4) schematically represents a prior art duo porcelain tile, FIG. 5 schematically represents a synthetic slab of the prior art, FIG. 6 schematically shows the arrangement of a terrace comprising slabs arranged on studs, - Figure 7) schematically shows a square decorative technical slab object of the invention, - Figure 8) schematically shows a hexagonal decorative technical slab object of the invention, - Figure 9) shows schematically. a square decorative technical slab object of the invention comprising an intermediate glue layer, - Figure 10) schematically shows the mold for producing a square decorative technical slab such as those shown in Figures 7) and 9), - Figure 11 .a) schematically represents a first step of a method of molding a square decorative technical slab such as that represented by Fig. 11b) shows schematically a second step of a method of molding a square decorative technical slab as shown in Fig. 7); Fig. 11.c) shows schematically a third step of a method of molding a square decorative technical slab such as that shown in FIG. 7), FIG. 11d) schematically represents a fourth step of a method of molding a technical slab Figure 12a) shows schematically a first step of a method of molding a square decorative technical slab such as that shown in Figure 9). FIG. 12b) schematically represents a second step of a process for molding a square decorative technical slab such as that represented in FIG. 9); FIG. 12.c) schematically represents a third Step 1 of a method of molding a square decorative technical slab such as that shown in Figure 9), - Figure 12.d) schematically shows a fourth step of a method of molding a square decorative technical slab as shown in FIG. 9), FIG. 12.e) schematically represents a fifth step of a method of molding a square decorative technical slab such as that shown in FIG. 9). Embodiments of the invention The present invention relates to slabs (10) decorative techniques. These are used in the realization of terraces or swimming pools. In accordance with the earth-moving techniques currently employed, the slabs (10) are intended to be placed on a bed of sand or on studs (30) as in the embodiment shown diagrammatically in FIG. 6. Referring to FIGS. ) to 9), the slabs (10) can take different forms (square, rectangular, hexagonal, octagonal, etc.) and different dimensions. For example, it is possible to make square slabs of 40cm, 45cm, 50cm, 60cm side or any other dimension suitable for the skilled person.

In the embodiment of terrace shown in Figure 6), slabs (10) of square shape are arranged next to each other in the 2937345 -9 way a checkerboard. Plots (30) supporting the slabs (10) are generally arranged at the corners of the slabs (10) and in the middle of their edges. The different pads (30) are adjustable in height so as to compensate for unevenness of the ground. It is thus possible to obtain a flat and level terrace.

Referring to Figures 7 to 8, the slabs (10) comprise an upper decorative layer (11) based on porcelain stoneware. The latter is the result of a mixture of clay and silica. The decorative layer (11) can be dyed in the mass by means of colored pigments and thus offer multiple patterns and colors: plain, cloudy, flamed, sandblasted, multicolored, etc. In general, the decorative layer (11) will have a thickness of a few millimeters to several centimeters. In practice during its manufacture, the porcelain stoneware is baked at a temperature of about 1300 ° C which vitrifies the material, the latter is pulverized and then molded by pressing (400 to 500 kg / cm 2).

As shown in Figures 7 to 8, the slabs (10) also comprise a lower support layer (12) on which is fixed the decorative layer (11). In practice, the support layer (12) has a thickness of one to several centimeters. This support layer (12) is made of a building material based on hydraulic binder. By hydraulic binder is meant a binder which forms and hardens by chemical reaction with water. The hydraulic binder may be in the form of cement, lime or any other binder suitable for the skilled person.

In practice, the slabs (10) are obtained by molding. Silicone mold (20) is preferably used, but molds made of cast iron, composite material or the like can also be used. As shown schematically in Figure 10, the mold (20) is in the form of a box (22) closed by a bottom (21) flat on its lower end and open on its upper end. The outline of the trunk has a general shape (square, rectangular, hexagonal, octagonal, etc.) and dimensions coinciding with the slab shape (10) that is desired. The inner walls of the trunk (22) may have scraps so as to facilitate the demolding of the slabs (10).

As shown in Figures 11.a) to 11.d), the manufacture of the slabs (10) comprises the following steps: - Referring to Figure 11.a), there is in the bottom of a mold ( 20) a decorative layer (11) consisting of a plate based on porcelain stoneware. In practice, the porcelain stoneware plate may have an often polished decorative face and a rough face intended to be applied to a floor. In such a configuration, the polished decorative face of the porcelain stoneware plate is disposed against the bottom (21) of the mold (20), the rough face facing the open end of the mold (20). In practice it will be advantageous to grind the decorative layer (11) in the factory before it is introduced into the mold (20) for better accuracy. Referring to Fig. 11.b), a support layer (12) of hydraulic binder construction material is cast onto the decorative layer (11). The support layer (12) naturally cures at room temperature in a few hours. with reference to FIG. 11.c), the slab (10) is demolded after hardening of the support layer (12). The demolding is carried out conventionally for example by turning the mold (20), by spacing the walls of the trunk (21) or by any other means suitable for the man of the trade. The slab (10) is then turned over as shown in Figure 11.d) and is then ready for use.

By way of nonlimiting example, this manufacturing method makes it possible, for example, to obtain a square slab (10) of 45 cm 3 cm thick, with a surface density of 70 kg / m 2.

In order to improve the adhesion of the layers to one another, it is cleverly to form asperities on the upper surface of the decorative layer (11) before casting of the support layer (12), said upper surface being the raw face of the layer decorative (11). These asperities may for example be obtained by scraping the upper surface.

In order to obtain a homogeneous support layer (12), said support layer is cast-vibrated on the decorative layer (11). Vibration of the support layer (12) can be achieved by means of a concrete vibrator, vibration of the mold (20) or by any other means suitable for the skilled person.

According to a first embodiment, the support layer (12) may be made of reconstituted stone. The reconstituted stone consists of natural elements crushed and recomposed with hydraulic binders. The support layer (12) of reconstituted stone is generally made in a trough, a mixing tank or a concrete mixer. The reconstituted stone and the hydraulic binder powder are first mixed homogeneously and dry. Then, clean water is added to the mixture. Advantageously, fiberglass may be mixed with the hydraulic binder so as to increase the mechanical characteristics of the support layer (12). Fiberglass is usually dry mixed directly with the hydraulic binder, but can also be mixed with the binder at the same time as the reconstituted stone is mixed with the binder.

In order to increase the cohesion between the decorative layer (11) and the support layer (12), the hydraulic binder of said support layer may also comprise a quartz-based cement adhesive. The quartz cement adhesive can be mixed with the binder in the same way as the fiberglass. Advantageously, the mixture comprises about two doses of quartz cementitious adhesive for one dose of binder, but may also include any other dosage suitable for those skilled in the art. Similarly, the hydraulic binder of the support layer (12) may comprise latex or other adhesive to increase the cohesion between the decorative layer (11) and said support layer.

Still with a view to increasing the cohesion between the decorative layer (11) and the support layer (12), and as shown in FIG. 9), the decorative layer (11) is fixed on the support layer (12) via an intermediate layer (13) of latex-based adhesive disposed between said decorative layer and said support layer. The intermediate layer (13) of adhesive has a thickness generally less than 5 mm. The latex-based glues are generally in the form of a viscous fluid easy to pour. In practice, and as shown diagrammatically in FIGS. 12 (a) to 12e), before casting of the support layer (12), an intermediate layer (13) of latex-based glue is poured onto the decorative layer (11). . According to an alternative embodiment, the hydraulic binder of the support layer (12) is of adhesive cement. By cementitious cement is meant a cement 2937345 -13- containing an adjuvant increasing its adhesion, the cement being a hydraulic binder widely known to those skilled in the art and consisting in particular of silicates and aluminates of lime, in variable proportions.

According to another variant embodiment, the support layer (12) is made of concrete. The latter is a composite construction material made from aggregates (sand, chippings) agglomerated by a hydraulic binder such as cement, lime, etc. The concrete support layer (12) is generally made in a trough, a mixing tank or a concrete mixer. The chippings, the sand and the hydraulic binder powder are first mixed homogeneously and dry. Then, clean water is added to the mixture.

Cleverly, and whatever the embodiment variant described above, a rigid reinforcement is embedded in the lower support layer (12). This frame can be metal fiber composite material, etc. The frame may be in the form of rods oriented in different directions, in the form of mesh or any other form suitable to the skilled person. In practice, during the manufacture of the slab (10), there is a reinforcement in the mold (20) on the decorative layer (11) before casting of the support layer (12). The support layer (12) is then cast onto the decorative layer (11) until the reinforcement is completely embedded. 25

Claims (14)

Revendications1. Decorative technical slab intended to be placed on studs or on a sand bed, characterized in that it comprises: - an upper decorative layer (11) based on porcelain stoneware, - a lower support layer (12) made of a material construction based on hydraulic binder and on which is fixed said decorative layer. 2. Slab according to the preceding claim characterized in that the support layer (12) is made of reconstituted stone. 3. Slab according to claim 2 characterized in that the hydraulic binder comprises a cement-based adhesive quartz. 4. Slab according to one of claims 2 or 3 characterized in that fiberglass is mixed with the hydraulic binder. 5. Slab according to one of the preceding claims characterized in that the decorative layer (11) is fixed on the support layer (12) via an intermediate layer (13) of latex-based adhesive disposed between said decorative layer and said support layer. 6. Slab according to claim 1 characterized in that the hydraulic binder of the support layer (12) is cement glue. 25 2937345 -15- 7. Slab according to claim 1 characterized in that the support layer (12) is concrete. 8. Slab according to one of the preceding claims characterized in 5 that a rigid armature is embedded in the lower support layer (12). 9. A method of manufacturing the slab according to claim 1 wherein: - there is arranged in the bottom of a mold (20) a decorative layer (11) 10 consisting of a plate based on porcelain stoneware, - a layer is cast support (12) of construction material based on hydraulic binder on the decorative layer (11), - the slab is demolded after hardening of the support layer (12). 15 10. The method of claim 9 wherein forming asperities on the upper surface of the decorative layer (11) before casting the support layer (12). 11. Method according to one of claims 9 or 10 wherein the support layer (12) is vibrated casting on the decorative layer (11). 12. Method according to one of claims 9 to 11 wherein sinks an intermediate layer (13) of latex based glue on the decorative layer (11) before casting the support layer (12). 2937345 -16- 13. Method according to one of claims 9 to 11 wherein there is a reinforcement in the mold (20) on the decorative layer (11) before casting of the support layer (12). 5 14. Method according to one of claims 9 to 13 wherein using a mold (20) of silicone.