US20100236170A1 - Flooring product and method for the production of the same - Google Patents

Flooring product and method for the production of the same Download PDF

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Publication number
US20100236170A1
US20100236170A1 US12/532,251 US53225108A US2010236170A1 US 20100236170 A1 US20100236170 A1 US 20100236170A1 US 53225108 A US53225108 A US 53225108A US 2010236170 A1 US2010236170 A1 US 2010236170A1
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US
United States
Prior art keywords
flooring product
color layer
binding agent
crystal structure
naturally grown
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/532,251
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English (en)
Inventor
Damian Dronia
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Individual
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Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of US20100236170A1 publication Critical patent/US20100236170A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • E04F13/144—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 of marble or other natural stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/28—Uniting ornamental elements on a support, e.g. mosaics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0438—Ornamental plaques, e.g. decorative panels, decorative veneers containing stone elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/06—Natural ornaments; Imitations thereof
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/006—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character
    • C03C17/007—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • 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
    • E04F13/0871—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 having an ornamental or specially shaped visible surface
    • 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
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2217/00—Coatings on glass
    • C03C2217/40—Coatings comprising at least one inhomogeneous layer
    • C03C2217/43—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase
    • C03C2217/46—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase
    • C03C2217/48—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase having a specific function
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials

Definitions

  • the invention relates to a flooring product and a method for the production of the same.
  • Generic flooring products are well known. They include, for example, floor tiles, wall tiles, panels etc., which may be coated with a layer of an attractive appearance, but which may also themselves consist of a material with an attractive appearance (e.g. stoneware, natural stone tiles). Flooring products can be applied directly onto the surface to be covered, but they can also be attached to carrier plates or the like. This is necessary, for example, if the underside of the flooring product is unsuited for attachment to an underlying surface.
  • agglomerate materials consist of various materials, such as sand, quartz, glass, ceramics, wood etc., and which are bonded with binding agents consisting of resins.
  • the different materials are crushed, mixed and combined with the adhesive agents.
  • the agglomerate is then compacted, hardened, ground, polished and cut to size.
  • the fact that the naturally grown structures of the starting materials are being destroyed during crushing proves to be a drawback in this process. It is thus impossible to design different surfaces in such a way that they exhibit a crystalline structure as it occurs naturally in nature.
  • a mineral is a naturally occurring solid with a uniform chemical composition and a structure which is homogeneous even on a microscopic level. Most minerals are crystalline. In nature, naturally grown crystal structures frequently occur in cavities of rocks. These may be filled with crystals of various types and are called druses or geodes. In the case of a druse, the wall of the cavity is covered with crystals, whereas in a geode, the entire interior is filled by crystals.
  • naturally grown crystal structures are called rough pieces or specimens.
  • the specimens are subdivided into two areas, a part which is colored throughout and a part which is not colored throughout.
  • the part colored throughout in turn is characterized by its naturally grown crown comprising freely crystallized minerals. Externally, they exhibit a fixed geometric shape with well-defined natural surfaces that are oriented in fixed angles relative to one another. This part of the specimen is also called color layer, whereas the part which is not colored is called root.
  • the above described rough pieces are generally very decorative, further use as a decorative material, such as in tiles, slabs or panels is almost impossible.
  • the individual pieces are too large, or too thick and have too great a weight. Accordingly, there is an interest in separating the non-colored part, that is, the root, which is superfluous as regards appearance, from the part that is of interest for decoration purposes, the color layer, without destroying the naturally grown crystal structures in the process.
  • the problem is that the crystalline build-up collapses as soon as the color layer is separated from the root. Moreover, the crystals of amethyst specimens, for example, lose their coherence amongst one another during the subsequent firing at the latest, so that the crystalline build-up collapses also in this case, when the color layer is separated from the crystal roots.
  • Citrine for example, is the yellow-colored variety of quartz. Depending on the provenance of the citrine and the cause of the coloration, the hue varies from pale greenish yellow over orange to brown-orange. However, natural citrines are so rare that almost exclusively artificial citrines or dyed quartzes are being sold commercially.
  • One variant of citrine production is based on the fact that violet amethysts, when heated to 300 to approximately 700° C., lose their violet color and take on an orange-yellow to brown color like a citrine. However, since the crystals of the amethyst specimens lose their coherence amongst one another during firing, as was already described above, it is not possible to produce artificial citrines that exhibit a naturally grown coherent build-up.
  • the object is achieved by a flooring product and a method for the production of such a flooring product, the surface of which consists of a naturally grown crystal structure which is held together by a binding agent, wherein the crystal structure consists of a color layer of a naturally grown mineral. Due to the binding agent, it is possible to reduce the weight and size of the respective crystal specimens without the naturally grown crystal structures falling apart.
  • the flooring product may consist of different crystal structures, such as, for example, the crystal structures of citrine, amethyst, quartz, pyrite, etc., depending on which type of crystal specimen or which rough pieces are being used.
  • the binding agent can be introduced into the interstices of the naturally grown crystal structure, and it can be a transparent adhesive of synthetic resin, such as, for example, a colorless two-component adhesive based on epoxy resin.
  • the flooring product can be bonded by means of a binding agent with a carrier plate which can consist of different materials, such as glass, plexiglass, ceramics, and which can have a plurality of different shapes and colors.
  • the surface of the flooring product according to the invention is sealed by the binding agent, so that no soiling, such as germs or fungi, can form in the interstices.
  • the crystal size of the flooring product preferably is 0.2 mm to 25 cm.
  • the binding agent is directly introduced into the interstices of the naturally grown crystal structures, the binding agent preferably being a transparent adhesive of synthetic resin, such as, for example, a colorless two-component adhesive based on epoxy resin.
  • the finished binding agent is preferably injected into the interstices of the crystals using thin needles.
  • the needles have an interior width of 0.5 to 0.8 mm, but can have a different interior width if necessary.
  • the pressure required for injecting the glue into the crystal interstices is generated, for example, by a Perfusor®. In principle, there is also the possibility of manually generating the pressure or to use other suitable devices.
  • the binding agent penetrates the crystal interstices more deeply than the needles themselves due to the capillary effect. In this manner, the crystal interstices are being firmly connected with one another far into the root.
  • the individual rough specimens already provided with the binding agents should harden.
  • the possible duration of hardening depends on external conditions, such as temperature, air humidity and the binding agent used, but is generally 24 hours.
  • the mixing ratio of possible binding agents in turn depends on the manufacturer's data and preferably should not deviate from them.
  • the bonded crystal roots can then be cut to size, with the naturally grown crystal structure not falling apart anymore. Cutting to size itself is preferably carried out on a gem saw. Subsequent to the separation of the color layer from the root, it is advantageous if the underside, that is, the side facing away from the naturally grown crystal structure, or the cut side, is ground smooth and polished, whereby a possible further processing of the flooring product is facilitated.
  • the flooring product according to the invention can not only be directly applied onto a surface to be covered, for example, a wall or ceiling of a room, but also be bonded to carrier plates by means of the same or a similar binding agent.
  • the carrier plates can consists of various materials, such as glass, plexiglass and ceramics and have various shapes and colors.
  • the surface of the flooring product is permanently sealed in a further step. Soiling of the surface by, for example, lime and other elements occurring in the water can thus be counteracted. The formation of germs and fungi in the interstices between the crystals can also be reduced or even prevented. This is particularly advantageous if the flooring product is used in sanitary rooms.
  • this method is carried out analogously to the first method.
  • the binding agent is not introduced directly into the interstices of the naturally grown crystal structures, rather, holes are drilled into the specimen between the color layer and the root, if possible directly underneath the color layer, using a drill, preferably a diamond drill.
  • the binding agent is introduced into these holes, and the holes should be drilled so close to one another that a complete gluing of the roots can be ensured.
  • the subsequent processing is carried out in the same way as in the first method.
  • a type of grinding putty is used as a binding agent.
  • the individual specimens must be heated in order for the necessary coherence between the grinding putty and the naturally grown crystal structure to be ensured.
  • the type of heating should in this case be selected such that a soiling of the naturally grown crystal structure is avoided. Heating on an electric plate has in this case proven particularly advantageous.
  • the specimens When the specimens are heated, they can be coated with a liquefied grinding putty.
  • the specimens already provided with the binding agents should subsequently harden prior to further processing also in this method. After the grinding putty has hardened, the crystals remain fixed and can be cut to size without falling apart when the color layer is separated from the root.
  • the cut flooring product is then applied either directly onto the surface to be finally coated, or onto a carrier plate.
  • the flooring product or the grinding putty, respectively, is then heated again so that the grinding putty can be removed again from the naturally grown crystal structure.
  • Cleaning the crystal structure for example by means of an alcohol-containing solution, is advantageous.
  • all three methods can also be combined with one another. It is also very important that it is generally not possible to exactly separate the color layer from the root; rather, the transition of the specimen from the root into the color layer, and thus, the position of the separation, is continuous. In order to obtain the color layer in as safe a manner as possible, separation is mostly carried out in the area of the root, as close to the color layer as possible. Thus, the binding agent can also glue the area of the root adjacent to the color layer, which automatically leads to the color layer not falling apart either.
  • the flooring product according to the invention can be joined on a surface, such as, for example, a carrier plate, a table, a wall or a tabletop. It is possible in the process that individual crystals have to be broken off from the flooring product so that adjacent flooring products can be better joined. It may also become necessary that individual interstices of adjacent flooring products have to be filled with individual crystals so that a more uniform total structure is created. It may be advantageous for such additional work to use the binding agent which was also used for the production of the flooring product.
  • a carrier plate mentioned above can consist of glass. Glass makes it possible to provide the finished product with a very high strength. In the process, the flooring product can be firmly bonded with the glass by means of a suitable binding agent. Tempered safety glass can be used if a predetermined breaking point is required. The latter can be produced using suitable cutting devices or machines. Moreover, laminated safety glass can also be used as a carrier plate if high pressures may occur during installation or later use, and if no predefined, predetermined breaking point is required. In the case of a possible processing using plexiglass, the latter is used in a preferred thickness of from 0.5 to 1.0 mm. Plexiglass has the great advantage that a significant reduction of the total load and a very low structural height can be achieved in the case of constructions having a limited or prescribed weight.
  • colored glass types or plexiglass in the hues of the stones to be used can be used.
  • the natural coloring of the minerals to be used can thus be enhanced.
  • the intensity of the transparency to light can be adjusted in a correspondingly variable manner. It is advantageous if the surface of the carrier materials is smooth on the side on which the flooring product is applied, and matte, rough or sandblasted on the other side.
  • Flooring products according to the invention can be used in a plurality of different areas of application.
  • the flooring product can be used, for example, as wall claddings, ceiling decorations and flat room decorations. Due to the low weight and low structural height, the flooring product is also suitable in areas in which a low weight is of decisive importance, such as, for example, in the construction of cruise ships, motor yachts and yachts. In the hotel and catering trade, the flooring product can be used, for example, for decorative purposes in wellness areas and restaurants.
  • the flooring product can also be used in the jewelry industry, for example in the production of belt buckles, pendants, tie pins, brooches or rings.
  • pendants for example, particular importance is attached to the rear.
  • a possible production of pendants with the flooring product could look like this: the rear of a piece of flooring product is ground and cut.
  • a flooring product of the same size can be produced from the same specimen, in which all sides, both the rear and the front with the naturally grown crystal structure, are ground and polished. The two parts can then be glued together by means of the binding agent, and the edges can also be ground and polished.
  • a pendant with a rear that matches in color, but is nevertheless smoothly polished, and with a front with a naturally grown crystal structure would thus be produced.
  • the processing of the flooring product can be carried out either on plexiglass carriers or directly on the surface to be covered.
  • FIG. 1 shows a specimen, or rough piece
  • FIG. 2 shows an already separated specimen with a non-colored root and a colored color layer
  • FIG. 3 shows a finished flooring product
  • FIG. 1 in which a specimen 60 , or rough piece, is to be illustrated by way of example. This is subdivided into a non-colored part, the root 61 , and a colored part, the color layer 61 .
  • the color layer 61 has a surface 40 in the shape of a naturally grown crystal structure 20 .
  • the naturally grown crystal structure 20 is held together in the root 62 . If the color layer 61 were separated from the root 62 , the naturally grown crystal structure 20 would lose its coherence and be destroyed.
  • a binding agent 30 is introduced into the interstices 21 of the naturally grown crystal structure 20 prior to the color layer 61 . being separated from the root 62 .
  • holes 80 are drilled into the specimen 60 between the color layer 61 and the root 62 , if possible directly underneath the color layer 61 , using a drill, preferably a diamond drill.
  • the binding agent 30 is then introduced into the holes 80 , so that a complete gluing of the crystal structure 20 ensured also in this method.
  • FIG. 2 shows a flooring product 10 according to the invention.
  • the interstices 21 filled with a binding agent are clearly visible.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Dispersion Chemistry (AREA)
  • Finishing Walls (AREA)
  • Floor Finish (AREA)
US12/532,251 2007-03-22 2008-03-12 Flooring product and method for the production of the same Abandoned US20100236170A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102007014496.4 2007-03-22
DE102007014496A DE102007014496B8 (de) 2007-03-22 2007-03-22 Verlegware und ein Verfahren zur Herstellung einer solchen
PCT/EP2008/052930 WO2008113726A1 (de) 2007-03-22 2008-03-12 Verlegeware und ein verfahren zur herstellung einer solchen

Publications (1)

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US20100236170A1 true US20100236170A1 (en) 2010-09-23

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US12/532,251 Abandoned US20100236170A1 (en) 2007-03-22 2008-03-12 Flooring product and method for the production of the same

Country Status (4)

Country Link
US (1) US20100236170A1 (de)
EP (1) EP2139700A1 (de)
DE (2) DE202007007508U1 (de)
WO (1) WO2008113726A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130000835A1 (en) * 2011-06-28 2013-01-03 Gem Center U.S.A., Inc. Easy break geode

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Publication number Priority date Publication date Assignee Title
EP2364864A1 (de) * 2010-03-10 2011-09-14 Kevin Golay System dekorativer Fliesenbeläge und dekorativer Friese und Herstellungsverfahrens dekorativer Fliesenbeläge und der dekorativen Friese
CN108973498A (zh) * 2018-07-31 2018-12-11 中国地质大学（武汉） 一种多层次立体饰品的制备方法

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US4076007A (en) * 1976-03-29 1978-02-28 Redlin Eugene E Gemstone drill
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130000835A1 (en) * 2011-06-28 2013-01-03 Gem Center U.S.A., Inc. Easy break geode
US8668000B2 (en) * 2011-06-28 2014-03-11 Gem Center U.S.A., Inc Easy break geode

Also Published As

Publication number Publication date
DE102007014496B3 (de) 2008-08-21
DE202007007508U1 (de) 2007-10-04
WO2008113726A1 (de) 2008-09-25
EP2139700A1 (de) 2010-01-06
DE102007014496B8 (de) 2008-11-27

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