Stone Mica Composite for Reduced Thickness and Impact Resistance
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Solution Overview
Problem
Existing multilayer materials using stone laminated with reinforcing elements are cumbersome, fragile, and limited in application due to their thickness and weight, requiring multiple reinforcing layers and interlocking systems that restrict their use to specific applications like flooring and wall finishing.
Innovation Solution
A multilayer material comprising a stone layer laminated with a mica plate or mica layer, which provides enhanced mechanical resistance, fire resistance, and reduced thickness, allowing for versatile applications with improved impact resistance and wave permeability, using a mica plate or mica layer as the reinforcing element with an adhesive layer and optionally a backing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If stone thickness is reduced to facilitate manipulation and reduce weight, then ease of operation and weight are improved, but fragility increases
Solution Approach 1:
The patent applies composite materials by laminating thin stone slabs (1-10mm) to a mica-based reinforcing layer. The mica plate provides structural strength and rigidity to the thin stone, enabling it to maintain low weight while avoiding fragility. This composite structure allows the stone to be thin enough for easy manipulation yet strong enough for practical applications.
2Strength
If multiple reinforcing layers are used to strengthen stone, then strength is improved, but device complexity and thickness increase
Solution Approach 1:
The patent extracts and eliminates the need for multiple reinforcing layers by using a single mica-based reinforcing element. The mica plate alone provides sufficient mechanical resistance, making additional reinforcing layers unnecessary. This simplification reduces structural complexity while maintaining the required strength for stone reinforcement.
Solution Approach 2:
The mica-based composite material provides high mechanical resistance in a single layer, replacing the need for multiple traditional reinforcing layers. The unique properties of mica (flexibility, strength, fire resistance) allow one layer to perform the function that previously required multiple layers of different materials.
3Strength
If traditional reinforcing elements are used, then strength is improved, but fire resistance and thermal performance deteriorate
Solution Approach 1:
The patent uses mica as the reinforcing material, which inherently provides both mechanical strength and superior fire resistance. Mica is a natural mineral with high thermal stability and fire-resistant properties, unlike traditional organic or metal-based reinforcing materials. This eliminates the trade-off between strength and fire resistance, as mica provides both properties simultaneously.
4Stability of the object's composition
If interlocking systems are used to connect multilayer materials, then stability is improved, but adaptability and ease of operation are reduced
Solution Approach 1:
The patent removes the interlocking system entirely, relying on the adhesive bonding between the stone slab and mica layer, plus the inherent flexibility of the mica, to provide structural stability. This elimination of complex interlocking mechanisms makes the material easier to manipulate, install, and adapt to various applications including curved surfaces and different thickness requirements.
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 multilayer material achieves a significant increase in impact resistance, reduced thickness, and improved fire performance, enabling its use in various applications from daily life devices to flooring and wall finishes with a thickness range of 2 to 40 mm, while maintaining durability and aesthetic appeal.
Implementation Method 1
the second face of said layer of stone and the first face of said layer of reinforcing element are laminated together at least by an adhesive layer
Data Source
AI summary
The present invention relates to a multilayer material comprising a layer of stone (1) laminated to a layer of reinforcing element (2) and its manufacturing process.