A composite stone panel

Abstract

The present disclosure relates to a composite stone panel. In one aspect, the panel is a benchtop. In one aspect the composite panel comprises a layer of a stone material attached to a base of an aerated ceramic composite material. In one form, the aerated ceramic composite material is an aerated porcelain composite. According to a further aspect, there is provided a method of manufacturing the above-described composite panel.

Description

A COMPOSITE STONE PANELPRIORITY DOCUMENTS

[0001] The present application claims priority from Australian Provisional Patent Application No. 2024901682 titled “A COMPOSITE STONE PANEL” and filed on 4 June 2024, the content of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to a composite stone panel.BACKGROUND

[0003] Natural, reconstituted or sintered stone features such as a benchtop and splashback are considered to be high-end features in a home. In addition to being aesthetically pleasing, natural, reconstituted or sintered stone is durable and can withstand heavy use and impact without incurring damage. A further advantage of a natural, reconstituted or sintered stone benchtop is that this material is highly heat-resistant making it ideal for use in the kitchen.

[0004] Unfortunately, natural, reconstituted or sintered stone is expensive, resulting in a significant demand for imitation products of lower cost, such as stone print laminates.

[0005] Moreover, the weight of natural, reconstituted or sintered stone makes handling and installation difficult. Natural, reconstituted or sintered stone requires significant structural support, and specialist skills and equipment to cut, handle and install.

[0006] It is against this background that the present disclosure was conceived.SUMMARY

[0007] According to a first aspect, there is provided a composite panel comprising a layer of a stone material attached to a base of an aerated ceramic composite material.

[0008] In one form, the aerated ceramic composite material is an aerated porcelain composite.

[0009] Porcelain is a type of ceramic, but porcelain is crafted from a mix of higher-grade clays and fired at more extreme temperatures than other ceramics. This makes porcelain harder and denser than ceramic tile, and also more durable and less porous.

[0010] In one form, in an alternative, the aerated ceramic composite material is an aerated earthenware.

[0011] In one form, in an alternative, the aerated ceramic composite material is an aerated stoneware.

[0012] In one form, the layer of stone comprises any one of, but need not be limited to, a natural, reconstituted or sintered stone.

[0013] In one form, the layer of stone and the base are attached using an adhesive.

[0014] In one form, the adhesive is a 2-pack adhesive.

[0015] In one form, the stone is any one of marble, granite, quartzite, travertine, dolomite or onyx. Natural or synthetic stone materials can be used.

[0016] In one form, the stone is a synthetic stone such as a porcelain and resin or cement-based terrazzo.

[0017] In one form, at an interface between them, both the layer of stone and the base comprise a substantially flat surface.

[0018] In one form, in an alternative, at an interface between them, both the layer of stone and the base comprise a matching and inter engaging profile.

[0019] In one form, this matching profile comprises peaks and troughs.

[0020] In one form, the aerated composite porcelain is made using recycled porcelain.

[0021] In one form, the aerated composite porcelain is a biproduct of porcelain tile production.

[0022] In one form, the stone face comprises a pair of opposing side surfaces and a substantially uniform thickness between this pair of side surfaces.

[0023] In one form, the base comprises a pair of opposing side surfaces and a substantially uniform thickness between this pair of side surfaces.

[0024] In one form, the pair of opposing side surfaces are substantially parallel.

[0025] In one form, the layer of stone panel comprises a thickness in a range of 1 mm to 15 mm.

[0026] In one form, the base of aerated ceramic material has a thickness in a range of 15 mm to 60 mm.

[0027] In one form, the base comprises at least one side edge surface.

[0028] In one form, a further layer of a stone material is attached to the side edge.

[0029] In one form, the base comprises a pair of parallel side edge surfaces.

[0030] In one form, a further layer of a stone material is attached to each of the pair of side edges.

[0031] In one form, the composite panel further comprises a sheet of fibre mesh between the layer of stone and the base.

[0032] In one form, a further layer of stone is provided, so that the base is sandwiched between two layers of stone.

[0033] In one form, the two layers of stone are comprised of the same or similar stone.

[0034] In one form, in an alternative, the two layers of stone are dissimilar stone.

[0035] In one form, adhesive is applied to both sides of the fibre mesh.

[0036] According to a first aspect, there is provided a composite panel comprising a layer of a stone material attached to a base of an aerated porcelain composite material.

[0037] According to further aspect, there is provided a method of manufacturing the above-described composite panel, the method comprising the steps of giving each of the stone layer and the base a substantially flat surface so as to create an interface for each, applying an adhesive to the interface of at least one of them and then joining them at the interfacing surfaces.

[0038] In one form, the substantially flat surface for the stone is formed with a saw.

[0039] In one form, the substantially flat surface for the aerated ceramic composite is formed with a saw.

[0040] In one form, the method comprises a further step of placing a sheet of fibre mesh between the layer of stone and the base.

[0041] In one form, the method comprises a further step of applying the adhesive to both sides of the fibre mesh.

[0042] In one form, the adhesive is applied to the interface of both the stone layer and the base.

[0043] According to a further aspect, there is provided a benchtop comprising a layer of a stone material attached to a base of an aerated ceramic composite material.

[0044] According to a further aspect, there is provided a benchtop comprising a layer of a stone material attached to a base of an aerated porcelain composite material.

[0045] In one form, the layer of a stone material attached to a top surface of the base.

[0046] In one form, the base comprises at least one side edge surface.

[0047] In one form, a further layer of a stone material is attached to the side edge.

[0048] In one form, a further layer of a stone material is attached to each side edge.

[0049] In one form, a mitre is formed into each layer of stone where these meet edgewise.

[0050] For ease of description, a composite panel embodying the present features is described below in its usual assembled position as shown in the accompanying drawings and terms such as front, rear, upper, lower, horizontal, longitudinal etc., may be used with reference to this usual position. However, the composite panel comprising may be manufactured, transported, sold, or used in orientations other than that described and shown here.BRIEF DESCRIPTION OF DRAWINGS

[0051] An aspect of the present disclosure will be discussed with reference to the accompanying drawings wherein:

[0052] Figure 1 illustrates a composite panel; and

[0053] Figure 2 illustrates two composite panels according to a further form.

[0054] In the following description, like reference characters designate like or corresponding parts throughout the figures.DESCRIPTION OF EMBODIMENTS

[0055] Referring now to Figure 1 , there is shown a composite panel 1. The panel 1 comprises a layer 2 of a stone material attached to a base 4 of an aerated ceramic composite material.

[0056] The stone could be any one of, but need not be limited to, a natural, reconstituted or sintered stone. The stone could be any one of, but need not be limited to, marble, granite, quartzite, travertine, dolomite or onyx.

[0057] In an advantageous form, the aerated ceramic composite material is an aerated porcelain composite. The aerated composite porcelain is made using recycled porcelain, which is a biproduct of porcelain tile production. This provides a strong, lightweight backing which minimises breakage of the stone.

[0058] The aerated porcelain is typically made by introducing air into a clay mixture before firing, creating a lightweight and porous material. This process involves several steps, including preparing the raw materials, mixing them into a slurry, introducing air through aeration, and finally, firing the material.

[0059] In addition to the porcelain powder, raw materials might include electrolytes, thinning agents, reinforcing agents, and pore-forming agents. These raw components are mixed with water to form a slurry of the required viscosity.

[0060] Air is introduced into the slurry, usually through a mechanical process like a propeller stirrer, to create air pockets within the mixture. This ensures the desired density and porosity of the final product.

[0061] The aerated clay mass is then molded into the desired shape using rigid molds.

[0062] The aerated clay is fired in a kiln at high temperatures, to harden the material and create the final aerated porcelain product.

[0063] Some light machining may be required to ensure flatness of faces and squareness of corners.

[0064] The stone layer 2 comprises a pair of opposing, parallel side surfaces and a substantially uniform thickness between this pair of side surfaces.

[0065] Similarly, the base 4 comprises a pair of opposing, parallel side surfaces and a substantially uniform thickness between this pair of side surfaces.

[0066] At an interface between them then, both the layer of stone 2 and the base 4 comprise a substantially flat surface.

[0067] The layer of stone 2 and the base 4 are attached using an adhesive, such as a 2-pack adhesive.

[0068] In a non-illustrated embodiment, the panel comprises a sheet of fibre mesh between the layer of stone 2 and the base 4. The adhesive is applied to both sides of the mesh. The mesh can become a part of the adhesive layer. The mesh increases the strength and bendability of an adhesive membrane on larger format pieces.

[0069] The fibre of the mesh could be either of a natural or a synthetic fibre. The fibre could be a glass fibre resin polymer (GFRP).

[0070] A method of manufacturing the above-described composite panel 1 would comprise the steps of giving each of the stone layer 2 and the base 4 a substantially flat surface so as to create an interface for each, applying the adhesive to the interface of at least one of them and then joining them at the interfacing surfaces. A band saw could be used to cut an interface for each of the stone layer 2 and the base 4. Adhesive could be applied to the interfacing surface of each of the stone layer 2 and the base 4. Clamps could be applied until the adhesive has bonded sufficiently.

[0071] Advantages of the present disclosure include:

[0072] 1. Reduced product weight when compared with solid stone only.

[0073] 2. The base 4 provides a reinforcing backing to minimize breakage of the stone layer 2.

[0074] 3. Reduced usage of non-renewable stone resources.

[0075] 4. A reduced and therefor safer lifting weight on building sites.

[0076] 5. A reduced level of silica carbonates when compared with solid stone products.

[0077] 6. Less skilled labour can install the product.

[0078] 7. Reduced risk of breakage during transportation and installation.

[0079] 8. Reduced requirement for specialty equipment to transport and install the panels.

[0080] 9. Any synthetic or natural stone product can be used in this panel system.

[0081] 10. Reduced cost of the raw product, by using a thinner veneer with the cost effective backing.

[0082] 11. With this combination it is possible to achieve slab sizes of 3300mm x 2000mm and of various thicknesses, in single slabs.

[0083] 12. Use of what would otherwise be a waste material i.e. using recycled porcelain.

[0084] The composite panel 1 according to the present disclosure is suitable for use in:

[0085] a) Benchtops;

[0086] b) External Building cladding;

[0087] c) Internal wall panels;

[0088] d) Stair building;

[0089] e) Tabletops;

[0090] f) Shelves;

[0091] g) Custom Furniture;

[0092] h) Bulk heads;

[0093] i) Splashbacks;

[0094] j) Rangehoods; and

[0095] k) Flooring.

[0096] Referring now to Figure 2, where there are illustrated two benchtops 100 and 100a according to the present disclosure. One of these benchtops 100a is illustrated inverted and laying atop of the other. Just as for the composite panel described above, each benchtop 100 and 100a comprises a layer 2 of a stone material attached to a base 4 of an aerated ceramic composite material.

[0097] For each of the benchtops 100 and 100a, the layer 2 of stone material is attached to a top surface of the base 4. In use, this layer 2 will provide a top of the benchtop.

[0098] Moreover, each of the benchtops 100 and 100a comprises a side edge surface to which a further layer 22 of a stone material is attached. A mitre is formed into each layer of stone 2 and 22 where these layers 2 and 22 meet edgewise. Further layers 22 of stone can be applied along each edge of the base 4which might be visible in the final installation, so that the base 4 is concealed, and the benchtop has the appearance of being made entirely of stone. This might be only a front edge, the front edge and one side edge, the front edge and both side edges, or a front edge, a back edge and both side edges.

[0099] The combining of aerated recycled porcelain panels and stone not only addresses practical needs but also contributes to sustainability and safety within the construction industry.

[0100] This combination is both environmentally more sustainable and preserves a nonrenewable resource. The safety aspect of the lightweight material will have significate benefits for the stone fabrication and installation industry.

[0101] The present disclosure provides a lightweight yet robust alternative to solid stone, meeting the demand for such materials on building sites while also reducing environmental impact and preserving valuable resources. The safety benefits for fabrication and installation further highlight the significance of this invention.

[0102] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that such prior art forms part of the common general knowledge.

[0103] It will be understood that the terms “comprise” and “include” and any of their derivatives (e.g. comprises, comprising, includes, including) as used in this specification, and the claims that follow, is to be taken to be inclusive of features to which the term refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied.

[0104] In some cases, a single embodiment may, for succinctness and / or to assist in understanding the scope of the disclosure, combine multiple features. It is to be understood that in such a case, these multiple features may be provided separately (in separate embodiments), or in any other suitable combination. Alternatively, where separate features are described in separate embodiments, these separate features may be combined into a single embodiment unless otherwise stated or implied. This also applies to the claims which can be recombined in any combination. That is a claim may be amended to include a feature defined in any other claim. Further a phrase referring to “at least one of’ a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c.

[0105] It will be appreciated by those skilled in the art that the disclosure is not restricted in its use to the particular application or applications described. Neither is the present disclosure restricted in its preferred embodiment with regard to the particular elements and / or features described or depicted herein.It will be appreciated that the disclosure is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope as set forth and defined by the following claims.

Claims

CLAIMS1. A composite panel comprising a layer of a stone material attached to a base of an aerated ceramic composite material.

2. The composite panel of claim 1 , wherein the aerated ceramic composite material is an aerated porcelain composite.

3. The composite panel of claim 1 or claim 2, wherein the layer of stone and the base are attached together using an adhesive.

4. The composite panel of claim 3, wherein the adhesive is a 2-pack adhesive.

5. The composite panel as in any one of the preceding claims, wherein the stone is any one of marble, granite, quartzite, travertine, dolomite or onyx, or porcelain and resin or cement-based terrazzo.

6. The composite panel as in any one of the preceding claims, wherein at an interface between them, both the layer of stone and the base comprise a substantially flat surface.

7. The composite panel as in any one of claims 2 through 6, wherein the aerated composite porcelain is made using recycled porcelain.

8. The composite panel as in any one of claims 2 through 7, wherein the aerated composite porcelain is a biproduct of porcelain tile production.

9. The composite panel as in any one of the preceding claims, wherein the stone face comprises a pair of opposing side surfaces and a substantially uniform thickness between this pair of side surfaces.

10. The composite panel as in any one of the preceding claims, wherein the base comprises a pair of opposing side surfaces and a substantially uniform thickness between this pair of side surfaces.

11. The composite panel of claim 9 or claim 10, wherein the pair of opposing side surfaces are substantially parallel.

12. The composite panel as in any one of the preceding claims, wherein the layer of stone panel comprises a thickness in a range of 1 mm to 15 mm.

13. The composite panel as in any one of the preceding claims, wherein the base of aerated ceramic material has a thickness in a range of 15 mm to 60 mm.

14. A benchtop comprising a layer of a stone material attached to a base of an aerated ceramic composite material.

15. The benchtop of claim 14, wherein the layer of stone material is attached to a top surface of the base.

16. The benchtop of claim 14 or claim 15, wherein the base comprises at least one side edge surface.

17. The benchtop according to any one of claims 14 through 16, wherein a further layer of a stone material is attached to the side edge.

18. The benchtop according to any one of claims 14 through 17, wherein a further layer of a stone material is attached to each side edge.

19. The benchtop according to either of claims 17 or 18, wherein a mitre is formed into each layer of stone where these meet edgewise.

20. A method of manufacturing the above-described composite panel, the method comprising the steps of giving each of the stone layer and the base a substantially flat surface so as to create an interface for each, applying an adhesive to the interface of at least one of them and then joining them at the interfacing surfaces.

21. The method of claim 20, wherein the substantially flat surface for the stone is formed with a saw.

22. The method of claim 20 or claim 21, wherein the substantially flat surface for the aerated ceramic composite is formed with a saw.

23. The method of any of claims 20 to 22, wherein the adhesive is applied to the interface of both the stone layer and the base.

24. The method of any of claims 20 to 23, wherein the method comprises a further step of placing a sheet of fibre mesh between the layer of stone and the base.

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