WO2006093367A1 - Panel - Google Patents

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Publication number
WO2006093367A1
WO2006093367A1 PCT/KR2005/000654 KR2005000654W WO2006093367A1 WO 2006093367 A1 WO2006093367 A1 WO 2006093367A1 KR 2005000654 W KR2005000654 W KR 2005000654W WO 2006093367 A1 WO2006093367 A1 WO 2006093367A1
Authority
WO
WIPO (PCT)
Prior art keywords
substrate
panel
adhesive
fiber mat
bonding layer
Prior art date
Application number
PCT/KR2005/000654
Other languages
French (fr)
Inventor
Chae-Goo Heo
Myung-Jong Ryu
Original Assignee
E & F Word Co., Ltd.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by E & F Word Co., Ltd. filed Critical E & F Word Co., Ltd.
Publication of WO2006093367A1 publication Critical patent/WO2006093367A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/02—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica the layer of fibres or particles being impregnated or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/06—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a panel, and more particularly to the panel in which a bonding layer is formed by coating adhesive on the surface of a substrate of a glass fiber mat or a rock fiber mat and a stone slab is adhered to the bonding layer, so that the material cost for installing a stone material such as natural marble as a finishing building material can be remarkably reduced, the construction cost can be lowered due to its simple treatment, thereby improving its practicality and securing the appearance of natural marble.
  • the terrazzo tile is excellent in construction and appearance, since a standard terrazzo tile is manufactured so as to have a size of below a predetermined value, many terrazzo tiles should be attached to a panel one by one to use the panel. Therefore, especially in case a wide area is constructed, the work efficiency of the panel is not good. Further, due to the portions among the tiles, the appearance of the panel is not considered to be preferable.
  • the imitation marble having the feel of a natural stone material is manufactured by forming crushed pieces of natural stones and an inorganic filling material together with a thermosetting resin and polishing a surface of the formed material.
  • the imitation marble should use relatively large-sized crushed pieces to realize the feel of natural material, but, in this case, the mobility of the mixed material deteriorates, thereby making the formation difficult. Further, cracks, breaks, and bends can be generated during the formation, so it is difficult to obtain a good formed material.
  • a panel attached with a sheet having a touch of natural stone material has a natural stone pattern effect on a printing sheet layer by using a gravure printing method, and then stacks a transparent vinyl sheet for protecting the pattern effect.
  • the panel natural pattern effect by printing method is not sufficient and is lacking in the durability of the transparent vinyl, so the panel is not suitable for replacing natural stone products. Disclosure of Invention Technical Problem
  • the present invention has been made in view of the above-mentioned problems, and it is an object of the present invention to provide a panel in which a bonding layer is formed by coating an adhesive on a surface of a substrate of a glass fiber mat or a rock fiber mat and a stone slab is adhered to the bonding layer, so that the material cost for installing a stone material such as natural marble as a finishing building material can be remarkably reduced, the construction cost can be lowered due to its simple treatment, thereby improving its practicality and securing the appearance of natural marble.
  • a panel comprising: a substrate(l); a bonding layer(2) formed by coating an adhesive on the surface of the substrate; a stone slab(3) bonded to the bonding layer(2); an insulating material(4) formed on the bottom surface of the substrate(l); and a cushioning material(5) formed on the bottom surface(l) of the insulating material.
  • the substrate(l) is a glass fiber mat or a rock fiber mat.
  • the material cost for installing a stone material such as natural marble as a finishing material can be remarkably reduced by coating the adhesive on a surface of the substrate of a glass fiber mat to form the bonding layer and attaching the stone slab to the bonding layer. Further, the construction cost can be lowered by facilitating its treatment and construction. Furthermore, the panel is excellent in practicability and has the appearance of natural marble.
  • the stone slab has a reinforced strength so as to reduce the load of a building and has an excellent insulating effect.
  • the strength of the substrate is reinforced by mixing magnesium in the rock fiber mat. Since an insulating material and a cushioning material are formed on the lower side of the substrate, the panel has noise blocking and soundproofing effects, and makes walkers feel comfortable.
  • FIG. 1 is an exploded perspective view for showing a panel according to the present invention.
  • FIG. 2 is a cross-sectional view for showing a panel according to the present invention. Best Mode for Carrying Out the Invention
  • FIG. 1 is an exploded perspective view for showing a panel according to the present invention
  • FIG. 2 is a cross-sectional view for showing the panel according to the present invention.
  • the panel according to the present invention includes a substrate (1), a bonding layer (2), and a stone slab (3).
  • a building panel (A) in which the stone slab (3) is firmly attached to a surface of the substrate (1) can be formed by coating an adhesive on the surface of the substrate to form the bonding layer (2) of a predetermined thickness and attaching the stone slab (3) to the bonding layer (2).
  • the substrate (1) is a glass fiber mat or a rock fiber mat, which is excellent in strength and non-inflammability.
  • the glass fiber mat and the rock fiber mat are manufactured by the following methods.
  • the glass fiber mat is manufactured by mixing an adhesive with glass fiber filaments, forming the glass fibers mixed with the adhesive so as to have a mat shape, and locating a non- woven fabric on the bottom surface of the formed glass fibers and spraying a thermosetting resin to fix the non-woven fabric.
  • Polyester or polypropylene is used as the adhesive to improve the bonding forces of the glass fibers. Since the non- inflammability of the glass fibers lowers if the mixing ratio of the adhesive exceeds 10 weight percent and the bonding forces of the glass fibers cannot be expected if the mixing ration of the adhesive is less than 1 weight percent, the adhesive of 1 to 10 weight percent is mixed with the glass fibers of 90 to 99 weight percent.
  • the non-woven fabric is directed to maintain the surface of the glass fiber mat.
  • the solidifying forces of the glass fiber tissues are reinforced and the surface of the glass fiber mat becomes smooth due to the non-woven fabric.
  • a thermosetting resin such as pozzolan is sprayed on the bottom surface of the non- woven fabric to fix the non- woven fabric and to make its surface smoother.
  • the non-woven fabric uses a spun bond of 100 percent polyester which has a melting point of over 200 degrees Celsius to maintain the surface of the non- woven fabric with the minimal amount, but the present invention is not limited thereto.
  • the rock fiber mat also used as the substrate (1) is manufactured by mixing an adhesive with rock fibers, forming the rock fibers mixed with the adhesive so as to have a mat shape, and spraying a thermosetting resin to fix the non- woven fabric to the bottom surface of the formed rock mat.
  • Polyester or polypropylene is used as the adhesive to improve the bonding forces of the rock fibers. If the mixing ratio of the adhesive exceeds 10 weight percent, the glass fibers lost its traits. If the mixing ration of the adhesive is less than 1 weight percent, the bonding forces of the glass fibers cannot be expected. Therefore, the adhesive of 1 to 10 weight percent is mixed with the glass fibers of 90 to 99 weight percent.
  • the non-woven fabric is provided to play the same role as used when the glass fiber mat is manufactured, the fixing method is also the same.
  • the substrate (1) is formed of the glass fiber mat or the rock fiber mat, it can endure a high temperature, can be noninflammable, can be strong to corrosion due to its chemical durability, can be excellent in strength, and can function as a lagging material, a cold insulation material, a sound-absorbing material, and a soundproofing material due to its insulating and soundproofing properties.
  • the bonding layer (2) for attaching the stone slab to the substrate (1) is formed by coating the adhesive on the glass fiber mat, i.e., the substrate (1).
  • the adhesive can c ontain either phenol resin or epoxy resin or acryl resin or polyester resin, or urethane resin. Likewise, various kinds of adhesives can be used with the spirit of the present invention.
  • the stone slab (3) can maintain the state in which it is adhered to the upper surface of the substrate (1), by pressing the stone slab (3), with the bonding layer (2) being interposed between the substrate (1) and the stone slab (3).
  • the stone slab (3) can be adhered to the substrate (1) not only by simply pressing the stone slab (3) or applying heat, but also by simultaneously applying heat and pressure to the stone slab (3), i.e., by hot-pressing the stone slab (3) or by using only the bonding layer (2) without applying any separate heat and pressure.
  • Either thin plate type building stone or tile or imitation stone can be used as the stone slab (3) adhered by the bonding layer (2).
  • a thin stone slab (3) such as thin plate type building stone, tile, and imitation stone can be used as stone slab (3) because of the strength.
  • the stone slab (3) is reinforced by the substrate (1) formed on the bottom surface of the stone slab (3). Therefore, the kind, the color, and the size of the stone slab (3) can be selected according to the design and the strength, which are required by the panel.
  • a separate insulating material (4) is additionally formed on the bottom surface of the substrate (1), the cold or heat from the outside of the panel (A) can be insulated.
  • a cushioning material (5) can be additionally formed on the bottom surface of the insulating material (4). In this case, the pressure applied to the stone slab (3) can be minimized by the cushioning material (5), the panel (A) can have elasticity, and the soundproofing effect.
  • the panel (A) provides walkers with excellent soundproofing and cushioning effect.
  • one or more than two of a non-woven fabric, latex, a honeycomb board, a veneer board, and a fiber can be used as the cushioning material (5).
  • the insulating material (4) or the cushioning material (5) is formed on the bottom surface of the substrate (1), it is also bonded by using an adhesive such as an epoxy resin.
  • the panel (A) according to the present invention is used as a flooring material or a finishing material for a wall at a building site.
  • the stone slab (3) attached to the substrate (1) is installed so as to be exposed to the outside, so it can maintain an appealing appearance. Further, since the weight of the panel is light compared with marble, a construction work can be carried out simply and speedily, thereby reducing the construction time and cost.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Textile Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Finishing Walls (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)

Abstract

The present invention relates to a panel, and more particularly to panel in which bonding layer is formed by coating adhesive on the surface of substrate of glass fiber mat or rock fiber mat and a stone slab is adhered to the bonding layer, so that the material cost for installing a stone material such as natural marble as a finishing building material can be remarkably reduced, the construction cost can be lowered due to its simple treatment, thereby improving its practicality and securing the appearance of natural marble. The panel comprises: a substrate(l); a bonding layer(2) formed by coating an adhesive on a surface of the substrate(l); a stone slab(3) attached to the bonding layer(2); an insulating material(4) formed on the bottom surface of the substrate(l); and a cushioning material(5) formed on the bottom surface of the insulating material(4).

Description

Description PANEL
Technical Field
[1] The present invention relates to a panel, and more particularly to the panel in which a bonding layer is formed by coating adhesive on the surface of a substrate of a glass fiber mat or a rock fiber mat and a stone slab is adhered to the bonding layer, so that the material cost for installing a stone material such as natural marble as a finishing building material can be remarkably reduced, the construction cost can be lowered due to its simple treatment, thereby improving its practicality and securing the appearance of natural marble. Background Art
[2] Recently, due to the high standard of living and the high grade trend of building materials, it has been generalized to apply natural stones of granite or marble to bottoms of main buildings such as department stores, office buildings, and large complex stores.
[3] Such natural stone panels are excellent in visual satisfaction and durability, but are so expensive that they can not be generalized at a construction site. Further, since they are so heavy that they are inconveniently treated and, in addition to the material cost of the marble itself, the construction cost is high compared with other construction materials, they are restrictively used in spite of their appealing appearances.
[4] Recently, in order to settle the problems of the above-mentioned stone panels, panels to which a terrazzo tile, an imitation marble, or a sheet having the feel of a natural stone material, which is excellent in construction and appearance, have been used.
[5] However, although the terrazzo tile is excellent in construction and appearance, since a standard terrazzo tile is manufactured so as to have a size of below a predetermined value, many terrazzo tiles should be attached to a panel one by one to use the panel. Therefore, especially in case a wide area is constructed, the work efficiency of the panel is not good. Further, due to the portions among the tiles, the appearance of the panel is not considered to be preferable.
[6] The imitation marble having the feel of a natural stone material is manufactured by forming crushed pieces of natural stones and an inorganic filling material together with a thermosetting resin and polishing a surface of the formed material. The imitation marble should use relatively large-sized crushed pieces to realize the feel of natural material, but, in this case, the mobility of the mixed material deteriorates, thereby making the formation difficult. Further, cracks, breaks, and bends can be generated during the formation, so it is difficult to obtain a good formed material.
[7] Further, a panel attached with a sheet having a touch of natural stone material, has a natural stone pattern effect on a printing sheet layer by using a gravure printing method, and then stacks a transparent vinyl sheet for protecting the pattern effect. However, the panel natural pattern effect by printing method is not sufficient and is lacking in the durability of the transparent vinyl, so the panel is not suitable for replacing natural stone products. Disclosure of Invention Technical Problem
[8] Therefore, the present invention has been made in view of the above-mentioned problems, and it is an object of the present invention to provide a panel in which a bonding layer is formed by coating an adhesive on a surface of a substrate of a glass fiber mat or a rock fiber mat and a stone slab is adhered to the bonding layer, so that the material cost for installing a stone material such as natural marble as a finishing building material can be remarkably reduced, the construction cost can be lowered due to its simple treatment, thereby improving its practicality and securing the appearance of natural marble. Technical Solution
[9] In order to achieve the above-mentioned object, there is provided a panel comprising: a substrate(l); a bonding layer(2) formed by coating an adhesive on the surface of the substrate; a stone slab(3) bonded to the bonding layer(2); an insulating material(4) formed on the bottom surface of the substrate(l); and a cushioning material(5) formed on the bottom surface(l) of the insulating material.
[10] The substrate(l) is a glass fiber mat or a rock fiber mat.
Advantageous Effects
[11] As mentioned above, according to the panel of the present invention, the material cost for installing a stone material such as natural marble as a finishing material can be remarkably reduced by coating the adhesive on a surface of the substrate of a glass fiber mat to form the bonding layer and attaching the stone slab to the bonding layer. Further, the construction cost can be lowered by facilitating its treatment and construction. Furthermore, the panel is excellent in practicability and has the appearance of natural marble.
[12] Further, by using the glass fiber mat or the rock fiber mat as the substrate, the stone slab has a reinforced strength so as to reduce the load of a building and has an excellent insulating effect. The strength of the substrate is reinforced by mixing magnesium in the rock fiber mat. Since an insulating material and a cushioning material are formed on the lower side of the substrate, the panel has noise blocking and soundproofing effects, and makes walkers feel comfortable.
[13] Further, due to the heat insulating function of the substrate, the generation of stains caused by condensation or molds can be prevented and the moisture, the cold, the heat, and the draft introduced through the panel can be blocked. Brief Description of the Drawings
[14] The foregoing and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[15] FIG. 1 is an exploded perspective view for showing a panel according to the present invention; and
[16] FIG. 2 is a cross-sectional view for showing a panel according to the present invention. Best Mode for Carrying Out the Invention
[17] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings, so that those skilled in the art can carry out the present invention.
[18] FIG. 1 is an exploded perspective view for showing a panel according to the present invention, and FIG. 2 is a cross-sectional view for showing the panel according to the present invention. As shown in FIG. 1 and 2, the panel according to the present invention includes a substrate (1), a bonding layer (2), and a stone slab (3).
[19] According to the panel (A) of the present invention, a building panel (A) in which the stone slab (3) is firmly attached to a surface of the substrate (1) can be formed by coating an adhesive on the surface of the substrate to form the bonding layer (2) of a predetermined thickness and attaching the stone slab (3) to the bonding layer (2).
[20] The substrate (1) is a glass fiber mat or a rock fiber mat, which is excellent in strength and non-inflammability. The glass fiber mat and the rock fiber mat are manufactured by the following methods.
[21] The glass fiber mat is manufactured by mixing an adhesive with glass fiber filaments, forming the glass fibers mixed with the adhesive so as to have a mat shape, and locating a non- woven fabric on the bottom surface of the formed glass fibers and spraying a thermosetting resin to fix the non-woven fabric. Polyester or polypropylene is used as the adhesive to improve the bonding forces of the glass fibers. Since the non- inflammability of the glass fibers lowers if the mixing ratio of the adhesive exceeds 10 weight percent and the bonding forces of the glass fibers cannot be expected if the mixing ration of the adhesive is less than 1 weight percent, the adhesive of 1 to 10 weight percent is mixed with the glass fibers of 90 to 99 weight percent.
[22] Further, since, if short staples are used as the glass fibers of the present invention, the tangling forces of the glass fibers become weak and the solidifying forces of the glass fibers get lower. Therefore, it is preferable to use filaments as the glass fibers.
[23] The non- woven fabric is directed to maintain the surface of the glass fiber mat. The solidifying forces of the glass fiber tissues are reinforced and the surface of the glass fiber mat becomes smooth due to the non-woven fabric. A thermosetting resin such as pozzolan is sprayed on the bottom surface of the non- woven fabric to fix the non- woven fabric and to make its surface smoother. The non-woven fabric uses a spun bond of 100 percent polyester which has a melting point of over 200 degrees Celsius to maintain the surface of the non- woven fabric with the minimal amount, but the present invention is not limited thereto.
[24] The rock fiber mat also used as the substrate (1) is manufactured by mixing an adhesive with rock fibers, forming the rock fibers mixed with the adhesive so as to have a mat shape, and spraying a thermosetting resin to fix the non- woven fabric to the bottom surface of the formed rock mat.
[25] Polyester or polypropylene is used as the adhesive to improve the bonding forces of the rock fibers. If the mixing ratio of the adhesive exceeds 10 weight percent, the glass fibers lost its traits. If the mixing ration of the adhesive is less than 1 weight percent, the bonding forces of the glass fibers cannot be expected. Therefore, the adhesive of 1 to 10 weight percent is mixed with the glass fibers of 90 to 99 weight percent.
[26] The non-woven fabric is provided to play the same role as used when the glass fiber mat is manufactured, the fixing method is also the same.
[27] Further, while the adhesive is mixed with the rock fibers, magnesium is mixed with the adhesive when the rock fiber mat is formed then, the strength of the formed rock fibers can be much better.
[28] Since the substrate (1) is formed of the glass fiber mat or the rock fiber mat, it can endure a high temperature, can be noninflammable, can be strong to corrosion due to its chemical durability, can be excellent in strength, and can function as a lagging material, a cold insulation material, a sound-absorbing material, and a soundproofing material due to its insulating and soundproofing properties.
[29] The bonding layer (2) for attaching the stone slab to the substrate (1) is formed by coating the adhesive on the glass fiber mat, i.e., the substrate (1). The adhesive can c ontain either phenol resin or epoxy resin or acryl resin or polyester resin, or urethane resin. Likewise, various kinds of adhesives can be used with the spirit of the present invention.
[30] The stone slab (3) can maintain the state in which it is adhered to the upper surface of the substrate (1), by pressing the stone slab (3), with the bonding layer (2) being interposed between the substrate (1) and the stone slab (3). The stone slab (3) can be adhered to the substrate (1) not only by simply pressing the stone slab (3) or applying heat, but also by simultaneously applying heat and pressure to the stone slab (3), i.e., by hot-pressing the stone slab (3) or by using only the bonding layer (2) without applying any separate heat and pressure.
[31] Either thin plate type building stone or tile or imitation stone can be used as the stone slab (3) adhered by the bonding layer (2). A thin stone slab (3) such as thin plate type building stone, tile, and imitation stone can be used as stone slab (3) because of the strength. The stone slab (3) is reinforced by the substrate (1) formed on the bottom surface of the stone slab (3). Therefore, the kind, the color, and the size of the stone slab (3) can be selected according to the design and the strength, which are required by the panel.
[32] Further, if a separate insulating material (4) is additionally formed on the bottom surface of the substrate (1), the cold or heat from the outside of the panel (A) can be insulated. If the panel (A) according to the present invention is used as a flooring material, a cushioning material (5) can be additionally formed on the bottom surface of the insulating material (4). In this case, the pressure applied to the stone slab (3) can be minimized by the cushioning material (5), the panel (A) can have elasticity, and the soundproofing effect. The panel (A) provides walkers with excellent soundproofing and cushioning effect.
[33] Then, one or more than two of a non-woven fabric, latex, a honeycomb board, a veneer board, and a fiber can be used as the cushioning material (5). In the case in which the insulating material (4) or the cushioning material (5) is formed on the bottom surface of the substrate (1), it is also bonded by using an adhesive such as an epoxy resin.
[34] The panel (A) according to the present invention is used as a flooring material or a finishing material for a wall at a building site. According to the panel A, the stone slab (3) attached to the substrate (1) is installed so as to be exposed to the outside, so it can maintain an appealing appearance. Further, since the weight of the panel is light compared with marble, a construction work can be carried out simply and speedily, thereby reducing the construction time and cost.
[35] Although this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, the invention is not limited to the disclosed embodiment and the drawings. It is intended to cover various modifications and variations within the spirit and scope of the appended claims.

Claims

Claims
[ 1 ] A panel comprising : a substrate(l); a bonding layer(2) formed by coating an adhesive on a surface of the substrate(l); a stone slab(3) attached to the bonding layer (2); an insulating material(4) formed on the bottom surface of the substrate(l); and a cushioning material(5) formed on the bottom surface of the insulating material(4).
[2] A panel according to claim 1, wherein the substrate(l) is a glass fiber mat or a rock fiber mat.
[3] A panel according to claim 2, wherein the glass fiber mat is manufactured by a method comprising the steps of: mixing an adhesive with glass fiber filaments; forming the glass fibers mixed with the adhesive; and locating a non-woven fabric on the bottom surface of the formed glass fibers and by spraying a thermosetting resin to fix the non-woven fabric.
[4] A panel according to claim 2, wherein the rock fiber mat is manufactured by a method comprising the steps of: mixing an adhesive with rock fibers; forming the rock fibers mixed with the adhesive; and locating a non-woven fabric on the bottom surface of the formed rock fibers and by spraying a thermosetting resin to fix the non-woven fabric.
PCT/KR2005/000654 2005-03-04 2005-03-09 Panel WO2006093367A1 (en)

Applications Claiming Priority (2)

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KR1020050018077A KR100519224B1 (en) 2005-03-04 2005-03-04 Laminated panel
KR10-2005-0018077 2005-03-04

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WO2006093367A1 true WO2006093367A1 (en) 2006-09-08

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EP2765255A4 (en) * 2011-10-03 2015-11-25 Candela Jose Juan Leva Self-adhesive natural-stone panel and method for the production thereof
EP3072679A1 (en) 2015-03-23 2016-09-28 FibreCem Holding AG Composite panel
WO2019053754A1 (en) * 2017-09-18 2019-03-21 Bagattini S.R.L. Process for applying an anti-fragmentation system to manufactured articles made of natural stone or ceramic and related manufactured article made of natural stone or ceramic
US11806982B1 (en) 2015-08-06 2023-11-07 Frontwave—Engenharia E Consultadoria, S.A. Multilayer laminate panel

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KR101235736B1 (en) 2009-06-04 2013-02-22 최철수 Panel for an interiors and exteriors, and method for manufacturing the same
WO2011025191A2 (en) * 2009-08-24 2011-03-03 Lee Sook Method for manufacturing ultrathin natural stone slab, ultrathin natural slab manufactured thereby and flooring using ultrathin natural slab
KR100945256B1 (en) * 2009-08-24 2010-03-03 이숙 Method for manufacturing ultrathin natural slab and ultrathin natural slab manufactured thereby
KR101132243B1 (en) 2010-02-01 2012-03-30 정진우 The prefab natural stone plate and its manufacturing method

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ITVI20090276A1 (en) * 2009-11-16 2011-05-17 Trend Group S P A MODULAR FLOORING STRUCTURE AND METHOD FOR THE CONSTRUCTION OF A MODULE OF THIS STRUCTURE
EP2765255A4 (en) * 2011-10-03 2015-11-25 Candela Jose Juan Leva Self-adhesive natural-stone panel and method for the production thereof
EP3072679A1 (en) 2015-03-23 2016-09-28 FibreCem Holding AG Composite panel
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