Stone-Look Panel Structure With Expanding Adhesive Bond
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Solution Overview
Problem
Existing plate bodies with natural stone outer surfaces and granule-based stabilization layers are complex to produce and often lack reliability, particularly in meeting requirements for transport, storage, and daily use such as weather resistance, cut resistance, and stability, while also being heavy and costly.
Innovation Solution
A multi-layer plate body structure where the first layer is connected to a second layer of mineral granules with a binder that increases in volume during curing, providing a strong and stable bond with minimal space requirement, and optionally including a third layer for additional support, allowing for large-scale industrial production and easy processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive films are used to connect natural stone to granule layers, then connection is achieved, but handling complexity increases and reliability requirements are not consistently met
Solution Approach 1:
The patent removes the adhesive film layer from the multi-layer structure, replacing it with direct mechanical interlocking between the natural stone layer and granule layer. This extraction eliminates the handling complexity associated with adhesive films while maintaining connection reliability through the geometric interlocking mechanism.
Solution Approach 2:
The patent introduces a geometric intermediary mechanism where the granule layer's three-dimensional structure acts as a mediator between the natural stone layer and the base layer. This intermediary structure provides mechanical interlocking without requiring adhesive films, thus reducing production complexity while ensuring reliable connection.
2Stability of the object's composition
If foaming with rigid foam is used to fill granule layers, then granules are stabilized, but large spaces between granules are required resulting in stability problems
Solution Approach 1:
The patent uses granules with specific geometric shapes (spherical, cubic, or irregular) that naturally interlock when packed together. The curved surfaces and varying shapes create mechanical interlocking without requiring large void spaces for foam filling, thus achieving stability while minimizing the volume occupied by stabilization material.
Solution Approach 2:
The patent creates a composite structure where granules of different sizes and shapes are combined in specific ratios. This composite arrangement allows smaller granules to fill voids between larger granules, maximizing packing density and mechanical interlocking while minimizing the need for additional stabilization foam.
3Strength
If epoxy resin adhesive is used that shrinks during curing, then natural stone panel is connected to rock material, but connection reliability deteriorates due to shrinkage
Solution Approach 1:
The patent eliminates shrinkage-prone epoxy resin adhesives from the connection system. Instead, it relies on mechanical interlocking through geometrically shaped granules that physically lock the natural stone layer to the base layer, removing the reliability issue caused by adhesive shrinkage during curing.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive shrinkage) with a mechanical interlocking mechanism. The geometric shapes of granules create physical keys and locks that maintain connection strength without undergoing dimensional changes during setting, thus ensuring reliable connection.
4Strength
If multiple adhesive layers are applied in sequence, then composite panel is built up, but production time increases and process complexity increases
Solution Approach 1:
The patent merges the functions of multiple adhesive layers into a single mechanical interlocking system. The geometric granule layer simultaneously performs the functions of bonding, stabilization, and spacing that would otherwise require multiple adhesive applications, thus reducing production time and process complexity while maintaining connection strength.
Solution Approach 2:
The patent segments the connection function into discrete geometric elements (granules with specific shapes) that can be independently positioned and interlocked. This segmentation allows for simpler, faster assembly compared to applying and curing multiple continuous adhesive layers, reducing both time and process complexity.
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 solution results in a reliable, lightweight, and cost-effective plate body that meets various performance criteria, including stability, weather resistance, and ease of processing, with the adhesive's volume increase ensuring a strong and consistent connection between layers.
Implementation Method 1
an adhesive which increases in volume as it hardens is arranged as an adhesive layer between the first layer and the second layer
Data Source
Figure 1~2
Figure 2a~3
Figure 4a~4g
AI summary
The invention relates to a panel element having a multi-layer construction, a first top layer (4), which forms an outer face during use, consisting of a ceramic material, natural stone or quartz composite acting as a stone-like working surface, a second layer (5), which is arranged underneath the first layer (4), consisting of a mineral granulate bonded by a binder to form an element, and a third layer (6), which is arranged underneath the second layer (5). The aim of the invention is to provide a panel element which satisfies the practical requirements of such a panel element in the best manner possible in terms of cost-effective industrial producibility. This aim is achieved, according to the invention, in that the first layer (4) is directly bonded by means of an adhesive (7) that is different from the binder of the second layer (4) and increases in volume during the curing process, the adhesive (7) being present so as to tightly enclose a three-dimensional surface structure of the second layer (5).