Ultra-thin Stone Composite Board Processing Method
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Solution Overview
Problem
Stone composite boards in architectural decoration are typically large in thickness and poor in bending performance and aesthetic appeal, leading to increased reject rates, cracking, and short service life due to degumming and peeling issues.
Innovation Solution
A processing method involving grinding and flattening natural stone boards to a preset thickness variation, followed by pressure-compositing with a base material layer using adhesive, calibrated planing with a diamond roller, and surface treatment to achieve a uniform and thin stone composite board with improved bending performance and aesthetic qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the thickness of stone composite board is reduced to improve bending performance, then the bending performance is improved, but the reject rate increases significantly and stone cracking and degumming occur
Solution Approach 1:
The patent changes the thickness parameter of the natural stone layer to an ultra-thin range (0.5-2.5mm) while compensating with improved adhesive layers and base material layers. This parameter change enables bending performance improvement while controlling reject rate through optimized thickness specifications and quality control measures.
Solution Approach 2:
The patent uses composite material structure combining ultra-thin natural stone layers with specially formulated adhesive layers and base material layers. The composite structure provides both bending performance and structural integrity, reducing cracking and degumming issues while maintaining acceptable reject rates.
2Duration of action of moving object
If the thickness of stone composite board is reduced to improve bending performance, then the bending performance is improved, but stone cracking and degumming occur during production process
Solution Approach 1:
The patent optimizes the thickness parameter of the natural stone layer to ultra-thin specifications (0.5-2.5mm) while adjusting the adhesive layer thickness and composition to compensate for the reduced stone thickness, preventing cracking and degumming during production and usage.
Solution Approach 2:
The patent introduces specially formulated adhesive layers as intermediaries between the ultra-thin natural stone layers and base material layers. These adhesive layers act as mediators that bond the components together while accommodating thermal expansion and contraction, preventing degumming and cracking.
3Ease of manufacture
If conventional adhesive bonding is used to connect base layers with stones, then the bonding is achieved, but the service life is short due to degumming and peeling
Solution Approach 1:
The patent changes the chemical and physical parameters of the adhesive layers, using high-strength adhesives with optimized viscosity, curing characteristics, and bond strength. This enables reliable bonding of ultra-thin stone layers while ensuring long service life by preventing degumming and peeling.
Solution Approach 2:
The patent uses composite adhesive layer structures combining multiple adhesive components and additives to achieve both easy bonding and long-lasting performance. The composite adhesive formulation provides initial bond strength for ease of manufacture while maintaining durability to prevent degumming and peeling over time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in stone composite boards that are uniform in thickness, dense, and firm, with enhanced bending performance, longer service life, and increased yield, allowing for effective decoration of curved surfaces while maintaining aesthetic appeal.
Implementation Method 1
carrying out pressure-compositing on the ground flattened natural stone board and a base material layer through an adhesive layer
Implementation Method 2
carrying out calibrated planing with a diamond roller on the natural stone layer
Data Source
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Figure 5~6
AI summary
The present application discloses a stone composite board and a processing method. According to a processing method of a stone composite board, the two sides of a natural stone board (31) are ground and flattened until a preset standard value of thickness variation is reached, then the surface planes and base material layers (1) are subjected to pressure-compositing through adhesive layers (2), afterwards splitting is conducted, and the natural stone layer is subjected to calibrated planing with diamond roller (5) and surface treatment to obtain the ultra-thin stone composite board. The stone composite board processed through the processing method is improved in bending property, flatness and wide in available size range. The composite structure is compact, firm and not liable to fall off. The service life is prolonged. Processing and cutting operations are facilitated, the yield is increased, and the construction effect and construction efficiency are improved.