WO2008022812A1

WO2008022812A1 - Flexible flat material with a natural stone surface

Info

Publication number: WO2008022812A1
Application number: PCT/EP2007/051452
Authority: WO
Inventors: Gernot Ehrlich
Original assignee: Gernot Ehrlich
Priority date: 2006-08-24
Filing date: 2007-02-14
Publication date: 2008-02-28
Also published as: DE202006013010U1

Abstract

The present invention relates to a flexible flat material having a surface layer (14) which comprises at least one layer of a multilayer stone material (20). The flat material has a flexible, pullable carrier layer (16), which carries the surface layer, and an adhesive layer (15) for fastening the flat material to a base.

Description

Designation: Flexible flat material with natural stone surface

The present invention relates to a flexible sheet, specifically a sheet having a decorative natural stone surface.

Materials such as slate, marble, granite and other types of bricks as well as various ceramic materials are commonly used to achieve a decorative appearance of floors, furniture surfaces and the like. Such materials are favorable in terms of their decorative appearance and wear resistance.

Despite these and other advantages, commonly used stone materials are generally relatively brittle and have limited flexural strength. In addition, the materials mentioned are heavy and inflexible, which limits the possibilities of using such materials for various applications. In addition, the attachment of such materials, for example, on floors or walls only with increased effort and with the aid of appropriate building materials such as mortar, cement or similar adhesive materials is possible.

In view of the characteristic features given above, for the use of stone materials, such as e.g. Slate, previously relatively complicated and expensive mounting or installation procedures needed. For example, a stone material generally can not be directly attached to a conventional wooden structure or subfloor because the support by a wooden structure is not sufficiently rigid and / or stable. This is due to the tendency of wooden structures to settle over time and to expand, contract or warp due to variations in temperature or humidity, and to sag when subjected to local stresses such as those experienced by a person walking over a floor. These dimensional changes can lead to cracking of numerous stone materials over time.

To solve the above-mentioned problems has been for the installation or installation of stone slabs and the like a rigid, in terms of their Stable base layer was made, which generally included a cement board over a subfloor of wood, bricks or any other building materials. Typically, a metal grid has been embedded in the cement to provide added strength to the plate. In some cases, more than one cement layer is required to achieve the required stiffness. The preparation of one or more such layers is tedious and time consuming. In addition, the requirements for special capabilities and / or additional costs may be associated with the manufacture of such a base layer. Further, in view of the weight of the cement base, for example, it may be necessary to additionally constructively reinforce a typical wooden floor, and consequently making a floor for laying stone materials may be laborious, time consuming and expensive.

Similar problems can arise when using stone materials as decorative elements of furniture, for example as part of a table top. This means that typically a rigid, dimensionally stable base layer is needed to form an adequate heavy stone liner support. In addition, the nature of the insert may be limited due to the relatively rigid structure of stone materials; Because stone can not be put around corners, edges and the like.

Attempts have already been made to make thin layers of stone material, e.g. Granite, for various decorative purposes by cutting or splitting produce. The granite thin slices are typically bonded to a metallic substrate to provide a support for the stone layer. Other decorative stone materials include split, relatively thin slates. These types of stratified stone products may have a reduced weight, thereby avoiding some of the problems associated with the use of stone materials. However, the products in question are still difficult to manufacture and require a lot of time and labor. Furthermore, layered stone products, such as e.g. Slate slabs, when produced in the form of relatively thin slices, are brittle and relatively brittle, and are easily destroyed by splitting and subsequently.

Furthermore, the use of stone materials for decorative surfaces in floors, furniture and the like due to the limited available limited to certain types of stone.

For example, various individual pieces of slate may have a unique, attractive and desirable appearance. However, such a single piece can only be used once for a particular application, such as part of a floor, thereby limiting the availability of such desirable attractive pieces for multiple use.

DE 295 08 372 Ul, for example, shows a flat material that solves many of the problems mentioned. However, the attachment to the ground is complicated and difficult even with this material.

Starting from the prior art, the object of the invention is to avoid the problems indicated above and to provide new possibilities for the creation of decorative stone surfaces, in particular natural stone surfaces. In particular, the decorative stone surface to be created should be easy and quick to install or process.

The task is achieved by a flexible sheet with

a surface layer comprising at least one layer of a multilayered stone material;

a flexible, conductive carrier layer which carries the surface layer,

- An adhesive layer for fixing the sheet dissolved on a substrate.

Thus, according to the invention, there is provided a flexible sheet material comprising at least one visible layer of a stone material made of a multilayered stone material, e.g. Slate, quartzite or the like has been replaced. The sheet further comprises a flexible backing layer adhesively bonded to that surface layer of stone material, which serves as a carrier for the stone material and provides the composite with the requisite tensile strength.

It has been found that a flexible flat material can be produced in which a flexible, tension-resistant carrier material is glued to a surface of a multilayered stone material and in which the flexible layer is then glued to the surface multi-layered stone material, wherein one or more layers of the stone material, which may be, for example, slate, be deducted together with the flexible layer of the surface of the stone material, since the flexible layer stronger at the top layer or the o- Upper layers of the stone material adhere to each other as the individual layers or layers of the stone material adhere to each other.

The flexible layer is preferably an adhesive synthetic resin layer adhered to the surface of the multilayered stone material. Depending on the type of synthetic resin used, the synthetic resin may, in some cases, be applied to the multi-layered stone material and withdrawn therefrom substantially immediately thereafter; in other cases, the resin must be allowed to harden to a greater or lesser extent before peeling to promote adhesion to the stone material.

Preferably, a tensile reinforcing material other than the adhesive resin, for example in the form of high-strength fibers admixed with the synthetic resin or applied as a separate layer, may be bonded to the stone material. When the reinforcing fibers are employed in the form of a separate layer, certain means are preferably employed to distribute the adhesive resin between the fibers such that they are sufficiently embedded in and secured within the adhesive resin to form a substantially uniform flexible layer to build. The flexible sheet obtained according to the invention exhibits a number of desirable properties and can be used for various applications. For example, although its surface layer is relatively thin compared to the multilayered stone material from which it was peeled, the sheet according to the invention has the appearance of the originally thicker and heavier stone material itself. Further, the sheet material according to the invention is relatively flexible and can be significantly bent - and withstand tensile loads. The flat material according to the invention can thus also be used on uneven surfaces and on corners and edges of a support to create a decorative surface, and of course on flat supports, such as floors, walls, roofs, doors, table tops, etc. Furthermore, the flat material according to the invention, although comprising a stone component, is relatively light, as a result of which the necessity for creating a rigid base layer of substantially stable dimensions is at least largely eliminated. In addition, a single piece of the stone material may serve to produce a large area of the sheet according to the invention by splitting it into its individual layers; this allows, as it were, the multiple use of a particularly beautiful and attractive piece of natural stone, which could hitherto be used practically only once.

A significant advantage of the invention is, in particular, that the flat material has an adhesive on its rear side facing the substrate, with which it can be glued to the substrate. For this purpose, plates or sections of the flat material are laminated on the backsides with such an adhesive. Suitable examples are acrylate adhesives or butyl rubber. Acrylate adhesive has a high bond strength and a very good peel strength. Depending on the amount of acrylate adhesive, the sheet is also suitable for vertical application because it is held securely due to the high holding power of the adhesive. Butyl rubber also has a high adhesive strength and is very soft, which is why this adhesive is particularly suitable for slightly uneven surfaces. Depending on the application, it may be useful to reinforce the adhesive layer of butyl rubber with a grid, preferably a fiberglass grid. Butyl rubber is particularly suitable for outdoor use.

The adhesive layer may be covered with a suitable film or similar covering as covering material, so that the flat material can be easily packed, stored and transported. On site, the film or pad is peeled off and the flat material glued directly to the substrate. As a result, high costs for the attachment of the sheet to the substrate are avoided by the usual methods, also attaching the sheet is very fast and easy to carry out.

Also suitable are adhesives that develop their adhesive power only under the application of pressure, but otherwise do not stick substantially.

The choice of a suitable adhesive depends on the individual conditions depending on location and / or the use of the flat material.

Further details and advantages of the invention are explained below with reference to a detailed description of preferred embodiments in conjunction with the accompanying drawings. Show it :

Fig. 1: a perspective top view of a flexible, decorative

Flat material according to the invention;

FIG. 2 shows a plan view of the flat material according to FIG. 1; FIG.

FIG. 3 shows a cross section through the flat material according to FIG

Figure 2 along the line 3-3 in Figure 2;

Fig. 3A: a greatly enlarged section of the cross section according to

FIG. 3;

Fig. 4 to Fig. 9: Illustrations for explaining the method for producing the flexible sheet material according to the present invention;

10 is a flowchart for explaining a modified embodiment according to the invention and

11 shows another embodiment of the invention

Process.

Before discussing a preferred exemplary embodiment of the invention in detail below with reference to the drawings, it should be stated that the person skilled in the art, on the basis of the exemplary embodiments, has numerous possibilities for changes and / or additions without having to abandon the basic idea of the invention.

Furthermore, it should be stated at this point that corresponding elements in the individual drawing figures are denoted by the same reference numerals and that in certain drawing figures certain details are not to scale, but rather enlarged to improve the clarity. are.

1 shows a perspective top view of an example of a substantially flexible sheet 10 according to the present invention. The sheet comprises a surface layer comprising at least one layer peeled off a multilayer natural stone material. As shown in Fig. 1, the sheet material according to the invention is integrated as a component in a floor covering material 12; However, the sheet material according to the invention may in principle be part of a number of articles, as will be explained in more detail below.

Although the surface layer of the sheet 10 is relatively thin compared to the multilayer natural stone material from which it was peeled off, the sheet 10 has the appearance of the originally thicker and heavier natural stone itself.

As shown in FIG. 2, the sheet 10 includes a visible surface layer comprising a plurality of different natural stone materials arranged to a desired pattern, for example, as shown in FIG. 2, into squares. The pattern may be a regular geometric pattern such as e.g. the square blocks or surfaces shown; but it can also be an irregular or abstract pattern.

Another possibility is that the sheet comprises a visible natural stone layer made from a single natural stone material.

Fig. 3 shows a cross section through the flat material 10 according to FIG. 1 along the line 3-3 in this figure and illustrates the components of the sheet material according to the invention. 3A shows a greatly enlarged section of the cross-section according to FIG. 3. As shown in FIGS. 3 and 3A, the generally flexible flat material 10 comprises a surface layer 14 comprising at least one layer of multilayer natural stone material, a flexible, extensible one As shown, support or support layer 16 is typically several times thicker than surface layer 14 and, in some instances, may be used as a load bearing support layer 16 bonded to surface layer 14, as well as an adhesive layer 15. lO times, 100 times or even 1000 times or more thicker than the surface layer.

The adhesive layer 15 may be covered before use by a cover layer, not shown, preferably formed from a film, which is deducted on site before sticking the sheet.

The surface layer 14 is shown as a substantially continuous surface layer. It is understood, however, that the surface of the surface layer will typically have significant discontinuities. This means that the surface of the surface layer has areas that have a greater or lesser number of natural stone layers compared to other areas. Furthermore, areas of the surface layer may be present in which the natural stone is missing, for example, at the points where the natural stone is broken away from the support layer in which the natural stone was not peeled off the multilayer or stratified natural stone material during manufacture, etc.

The surface layer may be made from a number of different natural stone materials, provided that the natural stone material comprises a plurality of relatively discrete layers, preferably those having substantially planar and parallel crystallographic orientation, which may be peeled off the natural stone material as sheets. The natural stone material may be a sedimentary material or, preferably, a metamorphic natural stone material, such as that resulting from progressive metamorphism of sedimentary rock by the action of mechanical forces, such as shear and compression forces, and / or by recrystallization forces under the influence of pressure and temperature. Preferably, the natural stone material is relatively rigid and suitable for splitting into relatively rigid and brittle leaves or fins, as is the case, for example, with slate, quartzite and the like. On the other hand, the natural stone material may be a layered rock, which consists of relatively flexible layers that can be easily split into individual layers, as is the case with mica, for example. The layered natural stone materials include those derived from clay, calcareous or quartzite sediments, and may include a variety of layering minerals such as mica, fluorites, quartz, hematite, clay and other materials. Examples of multilayered natural stone materials include, but are not limited to, schist, quartzite, mica, and the like. The natural stone material can, as described above, be a natural material or also comprise one of the known artificially produced stone materials.

Preferably, the natural stone material is slate. As one skilled in the art knows, there are many different types of slates, any of which can be used to make a sheet according to the invention. The different types of slate may have different characteristics, e.g. different colors, layer thicknesses, interlayer bond strengths, brittleness, etc. As those skilled in the art will also appreciate, the individual shales may themselves include differently colored layers, for example, differently colored layers of minerals resulting from the deposition and transformation of various materials during formation of the rock. This characteristic property constitutes one of the advantageous properties of the invention; Namely, when single-layered and / or multi-layered layers are peeled off a slate material to produce the sheet material according to the invention, as will be explained later, each piece of this sheet material has a unique and distinguishable appearance. As examples of highly desirable decorative slate materials, Indian slate and South African slate should be mentioned here because they have characteristic, unusual and bright colors; however, as mentioned above, in principle, many layered natural stone materials can be used. For the sake of simplicity, in the present description, almost throughout the term "slate" is used to designate a relatively arbitrary layered natural stone material.

Normally, the slate layer which is peeled off to form the sheet material according to the invention is extremely thin and not a self-supporting layer. The sheet material according to the present invention therefore also comprises a carrier layer 16, which is glued to the surface or slate layer 14. The carrier layer 16 is formed by a flexible, tensile, load-bearing, preferably reinforced material. Thus, the carrier layer 16 forms a carrier for the surface layer and imparts flexibility to the natural stone component such that the surface layer can withstand significant bending and / or tensile forces, with minimal, if any, breakage of the stone material. This is particularly advantageous because, as mentioned above, the rock material from which the natural stone component of the sheet is peeled off is relatively rigid per se and must be supported by a rigid support to prevent cracks. The carrier layer is also used in the process of the invention to form the sheet, as will be explained in more detail below.

The carrier layer 16 preferably comprises an adhesive resin. In the case of some high strength engineering resins, the strength of the resin is sufficient to impart the desired tensile strength to the backing. Alternatively, a flexible, tension-resistant carrier material can be used, which is different from the synthetic resin of the carrier layer 16 used as an adhesive. Such high tensile strength materials are known and are illustrated in FIGS. 3 and 3A in the form of a plurality of high strength fibers 18 embedded in the adhesive resin layer 16. High strength fibers are also known and include organic and inorganic reinforcing fibers, e.g. Glass fibers, carbon fibers, KEVLAR fibers, boron fibers and the like. The fibers may be in the form of cut single fibers, in the form of a woven or non-woven fabric, in the form of a mat, in the form of a sheet of substantially continuous filaments, in the form of a strand or strand of fibers, and so on. Other non-fibrous reinforcing materials are also known and may be used in addition or instead, as would be obvious to those skilled in the art.

The resin acting as an adhesive may be a thermoplastic or thermosetting resin. Thermosetting resins are currently preferred. The polymer can be used or dyed with its natural color to impart a color to the resin and thus to the backing layer that is beneath the shale layer. Suitable polymers for making the adhesive resin component of the flexible backing of the sheet according to the present invention include saturated and unsaturated polyolefins such as polyethylene and polypropylene; Vinyl polymers and copolymers such as, polyvinyl chloride (PVC), polystyrene and the like; acrylate polymers, such as polymers and copolymers of acrylic and methacrylic acid and their amides, esters, salts and corresponding nitriles; polyamides; Polyester; epoxy resins; polyurethanes; Mixtures and copolymers of these and other thermoplastic and thermosetting polymers, such as acrylonitrile butadiene styrene (ABS); and the same. Preferably, the polymer is selected so that the support layer adheres strongly to a surface of the layered rock material during manufacture, as described below, to such an extent that at least one shale layer is readily peeled from the rock and then the surface layer of the final product 10 forms. Examples of high adhesion synthetic resins are unsaturated polyesters, thermosetting and moldable or coating resins, etc., as well known in the art. These materials include a styrene-containing polyester resin in the form of solution UN1866, FRPA 505EC25 available from Ashland Chemical Company.

Polyester polymers useful in the practice of the invention include polycondensation products of a dicarboxylic acid with a dihydroxy alcohol, and these products can be obtained from a number of starting reagents, including: maleic, fumaric, and phthalic acids ( Isophthalic acid, terephthalic acid, etc.), adipic acid and other acids and their anhydrides, and ethylene, propylene, diethylene, dipropylene, 1,4-butylene and hexamethylene glycol, and the like. As desired, crosslinking agents may be added to the reaction product, for example, ethylenically unsaturated monomers such as e.g. Styrene and diallyl phthalate with the aim of cross-linking the unsaturated polyester so that it becomes thermosetting.

Acrylate polymers useful in the practice of the invention are obtained from various acrylic monomers such as acrylic and methacrylic acids and their amides, esters, salts and the corresponding nitrides. Particularly suitable monomers for such polymers are methyl methacrylate, Ethylacrelat and acrylonitrile. The polymers can be used in each case in the form of homopolymers or with various other monomers which thus permit copolymerization. Additional illustrative examples of acrylate polymers useful in the present invention are polyacrylates and polymethacrylates. which are homopolymers or copolymers of an acrylic acid ester or of a methacrylic acid ester, for example an isobutyl polyacrylate, a polymethyl methacrylate, a polymethacrylic acid ethylhexyl ester, a polyacrylic acid ethyl ester, copolymers of the various acrylates and / or methacrylates, such as methyl methacrylate / Acrylsäurecyclohexylester copolymers and copolymers of acrylic acid esters and / or with acrylic acid esters with styrene and / or alphamethylstyrene, such as the proppolymers and copolymers and polymer blends, which are composed of acrylic acid esters, methacrylic acid esters, styrene and butadiene.

Urethane polymers useful in the practice of the present invention are prepared by reacting a polyisocyanate, e.g. Toluene diisocyanate, diphenylmethane diisocyanate and hexamethylene diisocyanate react with a compound having at least two active hydrogens, e.g. Polyol, polyamine and / or polyisocyanate. Numerous polyurethane resins useful in the practice of the invention are available.

It is also possible to use various epoxy resins which are prepared by giving an epoxide group (resulting from the union of an oxygen atom with two other atoms, usually carbon), e.g. Epichlorohydrin, or oxidized polyolefins, e.g. Ethylene oxide, with an aliphatic or aromatic alcohol, e.g. Bisphenol A, glycerol etc. brings to reaction.

Furthermore, adhesives of vinyl polymers known in the art, e.g. Polyvinyl chloride, polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetates, polyvinyl ethers, polystyrenes and copolymers of these substances.

Preferably, the decorative sheet comprises a substantially transparent or translucent protective layer on the outer surface of the rock layer opposite the support layer. A protective layer may be applied to the surface of the natural stone component of the laminated sheet using any of the conventional methods of applying a protective layer of a polymeric material or other material to the surface of a material. These include, for example, the Spraying a solution or dispersion of a polymer or prepolymer onto the surface of the material, applying a polymer or prepolymer to the surface of the material by conventional coating means such as an opposing coating roll, a doctor blade, etc., or the like. Preferably, the polymer of the protective layer can penetrate at least into a part of the rock material and / or impregnate it. Polymers suitable for the formation of such protective layers are preferably weather-resistant polymers selected to form a layer which does not significantly delaminate or crack when exposed to environmental conditions for the intended use of the product, for which the decorative rock flat material is made. These weather-resistant polymers include fluoropolymers, acrylate polymers, urethane polymers, vinylpolymers and mixtures and copolymers of these polymers. Fluoropolymers useful in the practice of the invention include polymers and copolymers prepared from trifluoroethylene, tetrafluoroethylene, hexafluoropropylene, monochlorotrifluoroethylene and dichlorodifluoroethylene. Copolymers of these monomers prepared using fluoroolefins, such as vinylidene fluoride, are also useful. Other illustrative examples of the fluoropolymers useful in the practice of the present invention include polyvinyl fluoride and polyvinylidene fluoride. The fluoropolymer may be a fluorinated ethylene / propylene copolymer (the easily prepared "FEP" resins) or a copolymer of ethylene and chlorotrifluoroethylene, such as that sold under the tradename "HALAR". Vinylidene fluoride / hexafluoropropene and vinylidene fluoride / perfluoro (alcylvinyl ether) tripolymers and terpolymers with tetrafluoroethylene are other exemplary fluoropolymers useful in the practice of the present invention.

An example of a process for producing a sheet material according to the invention will now be explained with reference to Figs. FIG. 4 shows a natural stone material 20 which is used to produce the surface layer 14 of the flat material 10. As stated above, several individual layered natural stone materials, such as shale pieces, may be arranged in a regular or irregular decorative pattern. Alternatively, a single slate piece can be used as a multi-layered slate material. As shown in Fig. 5, an adhesive resin layer 22 may be applied to the exposed surface of the slate. The adhesive resin may be applied to the exposed surface of the slate or other multilayer natural stone material using any method known in the art for applying a polymeric coating to the surface of a material. These methods include, for example, spraying a solution or dispersion of the polymer onto the surface of the material, coating the surface of the material by means of conventional coating equipment, such as a counter-rotating coating roller, squeegee or the like, etc.

It will be understood by those skilled in the art that the adhesive resin binds to the surface of the layered rock material by chemical or mechanical forces, typically primarily mechanical forces. Thus, the surface of the layered rock material is preferably rough, or at least microscopically irregular, i. porous or microporous, or includes cracks or the like such that a physically sufficiently discontinuous surface results to permit mechanical adhesion of the resin thereto.

As mentioned above, the backing layer has sufficient tensile strength to peel at least one layer of rock material away from the layered rock without tearing and without significantly deforming. Depending on the properties of the selected adhesive resin, even the resin itself may have sufficient tensile strength to meet these requirements. Another possibility is shown in FIG. 6 is to use in combination with the adhesive resin of a different tensile, adhesive synthetic resin. In Fig. 6, the adhesive layer 22 is provided with a mat 24 of high-strength fibers. An adhesive synthetic resin layer 26 can additionally be applied to the high-strength fiber material according to FIG. The resulting laminate of first adhesive resin, a fiber mat and a second adhesive resin may then be pressure applied to ensure that the adhesive resin is evenly distributed between the high strength fibers and that the fibers are sufficiently absorbent embedded in the adhesive resin and in to be secured.

Colorants such as dyes and pigments may also be added to enhance the appearance of natural stone in the final product.

Alternatively, the fibers and adhesive resin may be mixed and simultaneously applied as a layer to the surface of the layered natural stone material 20, such as by extrusion, spraying, coating, etc. One or more layers of the fiber / resin mixtures are applied as needed.

After applying the backing layer to the surface of the natural stone material, the adhesive or resin is allowed to dry and / or cure as necessary to obtain a unitary, flexible, tension-resistant backing layer 16 bonded to the layered natural stone material 20 or glued. It will be understood by those skilled in the art that curing of certain types of adhesive plastics is not required.

As shown in FIG. 8, the backing layer 16 is subsequently peeled off the surface of the layered natural stone material 20, as indicated by an arrow 21. When the backing layer 16 is peeled off the fused stone material 20, at least one layer - in some cases multiple layers - of the layered natural stone material 20 adhered to the backing layer 16 is also peeled from the natural stone material. This leads to the formation of the surface layer 14 of the flat material 10.

The number of layers lifted off the surface of the stone material may vary depending on the particular adhesive material used, the process conditions (as discussed below), the nature of the layered natural stone material, and other parameters.

Typically, the one or more natural stone layers adhered to the backing layer 16 and peeled off the layered natural stone material 20 are quite thin compared to the thickness of the layered natural stone material 20, and even several raised natural stone layers, as they normally do, are still quite high overall are thin. the Na turkish layers may be substantially uniform and smooth over the surface of the sheet; however, the natural stone layers typically vary in number and thickness in each direction of the sheet. This can be very beneficial and desirable because it results in a textured appearance and grip of the surface of the sheet. In some cases, the one or more natural stone layers may contain numerous cracks formed during the peeling process; however, the cracks are not visible, so the thin stone layer appears like a single massive stone. Further, as mentioned above, various types of layered natural stones may include differently colored layers. Thus, the sheet may have variations in color and shades over the extent of its surface.

With respect to the particular angle at which backing layer 16 is peeled off, no critical conditions are assumed as long as the angle with respect to the surface of natural stone material 20 is not so great as to provide clearly visible cracks and breaks in the peeled thin surface of the stone material the layer 14 of the sheet material according to the invention can be seen. Preferably, the angle with respect to the surface of the natural stone material is less than about 90 °. However, the angle may be varied individually depending on various factors, for example, depending on the peeling speed, the applied tensile forces and the like.

The peel operation is best illustrated in FIG. 8A, in which a greatly enlarged partial cross-section through the material of FIG. 8 is taken along line 8A-8A in this figure. As shown, when the carrier layer 16 is pulled off the surface of the natural stone material 20, a portion of the adjacent natural stone material 20, ie at least one layer of the natural stone material 20, is detached from the surface of the natural stone material. In contrast, in the region of the natural stone material 20 from which the carrier layer 16 has not yet been peeled, there are no layers detached from the surface of the natural stone material. This shows that the thickness of the natural stone material used after stripping is less, even if only by a small amount, and makes it clear that the detached layer or the detached layers, based on the dimensions of the carrier Layer are relatively thin.

As mentioned above, the number of stone layers adhered to the carrier layer and released from the natural stone material may vary. The number of layers removed depends on various factors, for example the nature of the natural stone material, the adhesion between the individual layers in the natural stone material, the depth of penetration of the adhesive synthetic resin into the natural material. It will be understood by those skilled in the art that various types of multilayer natural stone materials may have at their surface a greater or lesser degree of irregularity and adhesion between adjacent layers, such that a greater amount of the adhesive resin may penetrate, or only one or more also several layers depending on the peel force can be solved. As stated above, the surface of the finally obtained sheet may have a variable thickness and may include, for example, areas where no stone material has been peeled off, areas where only one layer has been peeled off, and areas where multiple layers of stone material have been peeled off.

The degree of penetration of the synthetic resin into the stone material and / or the magnitude of the adhesive force of the adhesive resin can be determined by choosing the appropriate resin composition, the temperatures, the time for which the resin material is applied, and the like. For example, to limit the amount of penetration, a thermosetting resin can be used which can be crosslinked and cured before significant penetration of the synthetic resin into the surface of the natural stone material. Alternatively, deeper penetration may be allowed if a thicker stone component is desired.

To promote and improve the ease of delaminating the layers of the multilayered stone material, it may be treated prior to or during peeling so as to reduce the adhesion between the individual layers thereof, for example, by wetting and impregnating the multilayered stone material and heating it. This may also allow, to some extent, control over the number of layers released from the multilayer natural stone material. As already mentioned in connection with FIG. 4, several pieces of multilayered stone material can be juxtaposed to obtain a desired pattern. The pieces of stone can be positioned so that each of them is close to the adjacent pieces of stone. Alternatively, an adhesive or mortar may be used to optionally position the individual pieces of stone at a distance from each other. In one embodiment of the invention, a release material, such as a fluoropolymer, a silicone, or the like, is applied to the top surface of the adhesive mortar that bonds the individual stone pieces together. This material may also be stripped from the stone surface and provide additional decorative features, such as the image of mortar filled joints. After the flexible sheet is made, excesses (protruding portions) of the base sheet can be cut off, as shown in FIG.

10 shows a flow chart which explains the preferred way of producing the sheet. According to block 30, the multilayer natural stone material is first laid out in the desired shape or with the desired pattern. Subsequently, the tensile carrier layer is then applied and adhesively bonded to the natural stone material, as indicated by the block 32. As mentioned above, the tension-resistant backing layer may be an adhesive layer or an adhesive layer in combination with additional tensile materials such as high strength fibers which may be provided in the form of a separate layer or which may be mixed in a single layer with the synthetic resin. The adhesive resin is then cured in the case of a thermosetting resin, or cooled in the case of a thermoplastic material, and the resin material is allowed to dry out or otherwise cure as needed in block 34 in the event that a solvent is present. The support layer thus obtained is then peeled from the multilayer rock material according to block 36 such that the flexible support layer peels off at least one layer of the multilayer rock material from the surface thereof due to the adhesive force developed by the flexible layer. If desired, a protective layer may be applied over the surface layer of the sheet so prepared in accordance with block 38. Finally, in accordance with block 40, adhesive and, if necessary, a covering layer are applied to the rear side. It can also be a series production, that is, a continuous production of the laminating flat material. 11 shows by way of example a continuous process for producing flat materials according to the invention. In this embodiment of the invention, the multi-layer stone material 20 can be directed onto an endless conveyor belt and transported in the longitudinal direction thereof, as indicated by arrows. The stone material initially passes under a coating or extrusion device 52 for applying an adhesive synthetic resin 54 to the stone material. As shown and described above, the adhesive plastic can be applied without additional tensile materials, depending on the particular tensile strength of the adhesive plastic used. Advantageously, however, fibers of high tensile strength, such as glass fibers, are applied to the material, as indicated at 56. The glass fibers may be mixed with the adhesive plastic before it is applied to the stone material, as shown at 58, or by means of a roller 60. be applied to the adhesive plastic. In addition, when the high tensile strength fibers are separately applied to the adhesive resin, for example, by the roller 60 or by spraying, etc., an adhesive synthetic resin may be applied to the fibers once more (not shown). The multilayer material then preferably passes under compression rollers 62, which can promote the formation of a unitary structure of the adhesive resin and fibers, if any, by exerting a downward pressure, as indicated by arrows. The material is then transported to the stripping device 64 which stretches the support layer, which is flexible as described above, from the multilayer stone material 20 under conditions such that the flexible support stratum peels at least one layer of the multilayer stone material from the surface thereof Adhesive force of the flexible layer. The stone material may then be fed farther downstream of a similar production line or returned to the beginning of the manufacturing line of FIG. 11, as indicated by an arrow, using conventional manufacturing, transportation and control systems and devices.

The sheet materials according to the invention can be used for various purposes. The flat material can be used, for example, as a surface coating be used to give a different surface to various carriers. As mentioned above, the sheet can be applied to a relatively flat support surface; but it can also be applied to an uneven surface. As examples, building surfaces, floors, floor coverings, tiles, fields on the outer surface of furniture, outdoor fields of walls and doors and the like should be indicated.

The examples explained above are only intended to explain the invention in more detail, but without restricting it to the exemplary embodiment.

Claims

claims

1. Flexible flat material with

- a surface layer (14) comprising at least one layer of a multi-layered stone material (20);

a flexible, supportable carrier layer (16), which carries the surface layer,

- An adhesive layer (15) for fixing the sheet on a substrate.

2. Flat material according to claim 1, characterized in that the surface layer (14) comprises a plurality of layers of the multilayered stone material (20).

3. The sheet material according to claim 1, characterized in that the surface layer (14) comprises at least one layer of the multi-layered stone material (20) which has been detached from the surface of a rigid multilayer stone material (20).

4. Flat material according to claim 1, characterized in that the surface layer (14) comprises at least one layer of a multilayer slate material as stone material (20).

5. The flat material according to claim 1, characterized in that it additionally comprises a protective layer (22) on which the flexible, tension-resistant carrier layer (16) opposite the side of the surface layer (14).

6. Flat material according to one of claims 1 to 5, characterized in that it is mounted on a substrate.

7. Flat material according to one of claims 1 to 6, characterized in that the adhesive layer (15) is formed by an acrylate adhesive.

8. Flat material according to one of claims 1 to 7, characterized net, that the adhesive layer (15) is formed by butyl rubber.

9. Flat material according to one of claims 1 to 8, characterized in that the adhesive layer (15) is covered by cover material, which is detached before the gluing of the flat material.