WO2019054953A1 - Flexible marble cladding and production method thereof - Google Patents
Flexible marble cladding and production method thereof Download PDFInfo
- Publication number
- WO2019054953A1 WO2019054953A1 PCT/TR2017/050428 TR2017050428W WO2019054953A1 WO 2019054953 A1 WO2019054953 A1 WO 2019054953A1 TR 2017050428 W TR2017050428 W TR 2017050428W WO 2019054953 A1 WO2019054953 A1 WO 2019054953A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- marble
- layer
- flexible
- fiber
- upholstery
- Prior art date
Links
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
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
-
- 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
- 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
- B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
-
- 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
- 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
- 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
Abstract
A flexible marble upholstery (10) comprising a marble layer (14) which makes it possible to be laid over all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets and has thickness by flexing into any desired shape, wherein it comprises at least one polymer layer (11) which enhances the strength and flexibility of the said marble layer (14), at least one fiber layer (12) which prevents breaking and cracking of the marble layer (14), at least one adhesive layer (13) which binds the marble layer (14), fiber layer (12) and polymer layer (11) each other.
Description
FLEXIBLE MARBLE CLADDING AND PRODUCTION METHOD THEREOF
Technical Field
The invention relates to marble upholstery and their production methods.
In particular the invention relates to a light and flexible marble upholstery intended to be used in construction, furniture, aircraft and shipbuilding industry, and for all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets, and to a method for its production.
Background Art
Marble is a construction material which is preferred by the user for decorative purposes. In the applications of the prior art, large scale marble blocks, called massive blocks, are shaped in desired forms by robotic wire cutting or cutting with CNC machines using scanning method. Since the used forms are shaped from very heavy marble blocks by wire cutting or cutting, the stone yields high amounts of losses. Due to the difficulties in reusing the losses from the cutting process, the marble demand is increased, resulting in more marble quarries to be found in forest and rural areas increasing deforestation. Therefore, these applications of the prior art causes negative environmental impacts.
Due to the difficulties in production and application methods of the marbles used, users and manufacturers suffer from increased labor costs. Since the fuel consumption during transportation increases depending on the weight of the load, shipping costs and difficulties emerge from the heavy weight of the mentioned marble blocks.
An example of flexible marble production is given in Chinese utility model document no. CN205870902 titled "Ultra-thin marble cutter". On the other hand, this technique neglects maintaining the strength of the marble while providing flexibility for it.
Therefore, having studied all technical literature, the apparent need to a light and flexible marble upholstery intended to be used in construction, furniture, aircraft and shipbuilding industry, and for all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets, and to a method for its production has made it necessary to make a development in the technical field concerned.
Object of the Invention
Present invention relates to a flexible marble upholstery which meets the abovementioned requirements, prevents possible disadvantages and provides additional advantages, and a method for its production
The object of the invention is manufacturing a light and flexible marble upholstery intended to be used in construction, furniture, aircraft and shipbuilding industry, and for all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets. A very thinly sliced marble plate can gain flexibility by adding polymer and fiber layers to it. Therefore, it becomes possible for the marble to gain a high flexibility without sacrificing its strength. Furthermore, a simpler and faster marble cutting method with a lower cost is obtained in comparison to the scanning method or use od CNC machinery.
A further object of the invention is to minimize the wastage during the cutting operation and reduce the marble requirement by enabling reuse. The flexible and formable marble forms reduce the amount of wastage and volume of the marble usage. Therefore, deforestation due to the marble quarries established on forest and rural areas to supply the marble demand is reduced.
A further object of the invention is to reduce the marble costs. Raw material and labor costs are reduced since the application methods of the flexible marbles to be used are simple. Furthermore, since the flexible marble is lightweight, transportation costs are also reduced, contributing to the total costs to be reduced. For example, when an onyx type of marble with a 3 cm thickness is used on a front, the load is 65-70 kg while on the other hand with a thinned marble, it is only 1 .5 kg/m2.
To achieve the abovementioned objectives in the most general manner, a light and flexible marble upholstery intended to be used in construction, furniture, aircraft and shipbuilding industry, and for all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets and a method for its production is developed. The developed flexible marble upholstery comprises at least one marble layer with a thickness that enables flexing into the desired form, at least one polymer layer which enhances the strength and formability of the marble layer, at least one fiber layer which prevents breaking and cracking of the marble layer, and at least one adhesive layer which binds the marble layer, fiber layer and polymer layer together.
Structural and characteristic features of the invention with all its advantages will become apparent with the detailed description in reference to the illustrations given below therefore assessments should be based on these illustrations and the detailed description.
Figures that Help Understanding the Invention
Assessments should be made in accordance with the figures given below to appreciate the structure and advantages of the present invention with further elements.
Figure - 1 : An exploded view of the flexible marble upholstery of the invention.
Figure - 2: A schematic view of the production method of the flexible marble upholstery of the invention.
Figure - 3: A front view of the cutting machine of the flexible marble upholstery of the invention.
Parts References
10 Flexible marble upholstery 29 Wheel
1 1 Polymer layer 30 Rail
12 Fiber layer A Preparation
13 Adhesive layer B Smoothing
14 Marble layer C Roughening
15 Production method D Adhesive application
20 Marble cutting machine E Polymer application
21 Hoop F Fiber application
22 Hydraulic system G Rolling
23 Motor H Cutting
24 Electrical panel I Molding
25 Saw J Polishing
26 Cutting table K Drying
27 Product X Horizontal axis
28 Machine foot Y Vertical axis
Detailed Description of the Invention
Using conventional marble blocks on curved surfaces such as exterior surfaces, columns and parapets are not possible due to their size and heavy weight. Therefore, marble should be formed into very thin slices. However in this case, there is a loss of strength and the thinned marble loses its features even without processing. The flexible marble upholstery (10) improved with the invention comprises a marble layer (14) which makes it possible to be laid over all kinds
of vertical or horizontal curved surfaces and has thickness by flexing into any desired shape. In contrast with the prior art, the marble layer (14) is provided with the strength required for forming, transportation and application by additional layer. The additional layers are: the polymer layer (1 1 ) which enhances the strength and formability or flexible form of the marble layer (14), the fiber layer (12) which prevents breaking and cracking of the marble layer (14), and the adhesive layer (13) which binds the marble layer (14), fiber layer (12) and polymer layer (1 1 ) each other.
Figure 1 gives an exploded view of the flexible marble upholstery (10) of the invention. In a preferred embodiment, the marble layer (14) is made of an onyx derivative marble. The fiber layer (12) which enhances the strength is made of glass material while the polymer layer (1 1 ) is made of polyester. The adhesive layer (13) for binding is preferably epoxy based.
A production method (15) whose schematic view is given in Figure 2 is developed to produce the flexible marble upholstery (10). The mentioned production method (15) essentially comprises the following process steps:
- the preparation (A) which is defining the marble, from which the marble layer (14) will be cut off,
- the smoothing (B) which is preparing for sanding the marble, from which the marble layer (14) will be cut off,
- the roughening (C) which is washing with sand the marble, from which the marble layer (14) will be cut off,
- the adhesive application (D) which is leading the adhesive layer (13) on the marble from which the marble layer (14) will be cut off,
- the polymer application (E) which is applying over a polymer layer (1 1 ) on the adhesive layer (13),
- the fiber application (F) which is laying over a fiber layer (12) on the polymer layer (1 1 ),
- the cutting (H) which the marble layer (14) is separated by cutting it off the marble block.
After the preparation (A) step which the marble is selected, the onyx/marble block with 50 cm thickness goes into smoothing (B) to remove its rough outer surface using a special marble cutting machine (20) which can be seen in Figure 3. The smoothened surface is then became available for adhesive application (D) by roughing homogenously with the roughening (C). The maximum dimensions of the surface over which the adhesive layer (13) is applied is 160x340 cm in size. Later on, the fiber application (F) is performed over the adhesive layer (13) after which it is left for drying (K). Cutting (H) starts before the drying (K) step is completed and a marble layer (14) of 2-3 mm thickness is separated from the block using a custom production marble cutting machine (20). After the cutting (H), it is customary to shape the marble layer (14) using a template and provide to drying (K) in this state. In the production method (15) and
during cutting (H), it is possible to have a tolerance of +/- 1 -2 mm within particular regions of the marble layer (14). Therefore the thickness of the 3 mm cut marble layer (14) may vary down to 2 mm in some areas or even can be as thin as 1 mm in some areas. Also mild cracks can form on the thicker areas while bending the flexible marble upholstery (10).
In the preferred embodiment of the production method (15), a rolling (G) process step takes place after the fiber application (F) step in order to provide a better bonding of the polymer layer (1 1 ) and the fiber layer (12) to the marble layer (14), where a roller is passed over it. At this point, adhesion to the marble layer (14) is provided by ensuring the polymer layer (1 1 ) and the fiber layer (12) to permeate each other. In addition, a further molding (I) step can take place where the marble layer (14) is formed with the desired shape within a mold. So the marble layer (14) is thereby formed into the permanent desired shape and then the marble layer (14) is polished during the polishing (J) process step.
In the 1 st production, before this material is dried, a top layer of 2 mm thickness is removed by holding it on the fiber sections using special holders. Later on, this removal process can be repeated for a 2nd and a 3rd time by returning back to the starting stage.
The marble cutting machine (20) given in Figure 3 comprises the following elements: a saw (25) which is used for cutting the block product (27), a hoop (21 ) which moves the saw (25), a motor which (23) drives the hoop, an electrical board (24) which supplies electrical current, a cutting table (26) over which the product (27) to be cut is laid over, the machine foot (28) which supports the marble cutting machine (20), wheels (29) that provide a smoother motion for the product (27), rails (30) that enable the product (27) to advance on the horizontal axis (x) during the cutting by providing a bearing for the machine feet (28), a hydraulic system (22) that sets the thickness of the product (27) to be cut by moving in upward and downward directions on the vertical axis (y) over the rails (30) and also in a similar manner enables the cutting table (26) to move in forward and backward directions on the horizontal (x) axis.
Claims
1. A flexible marble upholstery (10) comprising a marble layer (14) which makes it possible to be laid over all kinds of vertical or horizontal curved surfaces such as exterior surfaces, columns and parapets and has thickness by flexing into any desired shape, it is comprising;
at least one polymer layer (1 1 ) which enhances the strength and flexibility of the said marble layer (14),
at least one fiber layer (12) which prevents breaking and cracking of the marble layer (14),
- at least one adhesive layer (13) which binds the marble layer (14), fiber layer (12) and polymer layer (1 1 ) each other.
2. A flexible marble upholstery (10) according to Claim 1 , wherein the said marble layer
(14) is preferably onyx.
3. A flexible marble upholstery (10) according to Claim 1 , wherein the said polymer layer (1 1 ) is preferably polyester.
4. A flexible marble upholstery (10) according to Claim 1 , wherein the said fiber layer (12) is preferably glass fiber.
5. A flexible marble upholstery (10) according to Claim 1 , wherein the said adhesive layer (13) is preferably epoxy based.
6. A flexible marble upholstery (10) according to claim 1 , wherein the production method
(15) comprises the following process steps:
- the preparation (A) which is defining the marble, from which the marble layer (14) will be cut off,
- the smoothing (B) which is preparing for sanding the marble, from which the marble layer (14) will be cut off,
- the roughening (C) which is washing with sand the marble, from which the marble layer (14) will be cut off,
- the adhesive application (D) which is leading the adhesive layer (13) on the marble from which the marble layer (14) will be cut off,
- the polymer application (E) which is applying over a polymer layer (1 1 ) on the adhesive layer (13),
- the fiber application (F) which is laying over a fiber layer (12) on the polymer layer (1 1 ),
- the cutting (H) which the marble layer (14) is separated by cutting it off the marble block.
- the cutting (H) during which the said marble layer (14) is separated by cutting it off the marble block.
A production method (15) according to claim 6, wherein a rolling (G) process step takes place after the said fiber application (F) step in order to provide a better bonding of the polymer layer (1 1 ) and the fiber layer (12) to the marble layer (14), where a roller is passed over it.
A production method (15) according to claim 6, wherein it comprises a molding (I) step that takes place where the said marble layer (14) is formed with the desired shape within a mold.
A production method (15) according to Claim 6, wherein it comprises a polishing (J) process step where the said marble layer (14) is polished.
A production method (15) according to Claim 6, wherein it comprises a drying (K) process step where the said adhesive layer (1 1 ) is dried.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/TR2017/050428 WO2019054953A1 (en) | 2017-09-13 | 2017-09-13 | Flexible marble cladding and production method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/TR2017/050428 WO2019054953A1 (en) | 2017-09-13 | 2017-09-13 | Flexible marble cladding and production method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2019054953A1 true WO2019054953A1 (en) | 2019-03-21 |
Family
ID=61683876
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2017/050428 WO2019054953A1 (en) | 2017-09-13 | 2017-09-13 | Flexible marble cladding and production method thereof |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2019054953A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT388013B (en) * | 1986-07-08 | 1989-04-25 | Leis Rudolf | Composite body |
| WO2009110870A1 (en) * | 2007-08-06 | 2009-09-11 | Fraser James D | Process and apparatus for creating ultra-thin stone veneer for exterior or interior cladding or decor |
| US20110027566A1 (en) * | 2008-03-28 | 2011-02-03 | Lg Hausys, Ltd. | Natural-stone composite panel and method of making the same |
| US20120276366A1 (en) * | 2011-04-28 | 2012-11-01 | Eric Toupin | Flexible slate veneer architectural panel |
| KR20160116542A (en) * | 2015-03-30 | 2016-10-10 | 최중갑 | Method and product of the stone cutting |
| CN205870902U (en) | 2016-07-28 | 2017-01-11 | 奇台县豪门石业开发有限公司 | Ultra - thin marble marble cutter |
-
2017
- 2017-09-13 WO PCT/TR2017/050428 patent/WO2019054953A1/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT388013B (en) * | 1986-07-08 | 1989-04-25 | Leis Rudolf | Composite body |
| WO2009110870A1 (en) * | 2007-08-06 | 2009-09-11 | Fraser James D | Process and apparatus for creating ultra-thin stone veneer for exterior or interior cladding or decor |
| US20110027566A1 (en) * | 2008-03-28 | 2011-02-03 | Lg Hausys, Ltd. | Natural-stone composite panel and method of making the same |
| US20120276366A1 (en) * | 2011-04-28 | 2012-11-01 | Eric Toupin | Flexible slate veneer architectural panel |
| KR20160116542A (en) * | 2015-03-30 | 2016-10-10 | 최중갑 | Method and product of the stone cutting |
| CN205870902U (en) | 2016-07-28 | 2017-01-11 | 奇台县豪门石业开发有限公司 | Ultra - thin marble marble cutter |
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