Lightweight Stone Panel With Textile Adhesive Layer
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Solution Overview
Problem
Existing methods are unable to effectively install large format natural stone or UHPC panels greater than 1.5×3 m due to weight and logistical challenges, and current adhesives are not suitable for gluing these panels to floors or walls.
Innovation Solution
A lightweight panel structure comprising a central core, an external natural stone or UHPC slab, a rear metal sheet, and a textile layer (fabric, non-woven fabric, or glass fiber mat) glued to the metal sheet, making it compatible with traditional cementitious adhesives and installation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large format natural stone or UHPC slabs are used to achieve high-end aesthetic appearance, then the aesthetic quality and prestige are improved, but the weight and logistical challenges increase significantly
Solution Approach 1:
The patent creates a composite panel structure combining a lightweight core (expanded polystyrene, polyurethane foam, or mineral wool) with thin natural stone or UHPC slabs (3-20mm) and metal sheets. This composite construction achieves the desired aesthetic appearance of thick natural stone slabs while reducing the weight to manageable levels for installation by ordinary workers, resolving the contradiction between aesthetic quality and weight.
2Ease of operation
If traditional cementitious adhesives are used for gluing panels, then the installation simplicity is improved, but the adhesive thickness requirement creates level compensation problems
Solution Approach 1:
The patent introduces a textile layer (fabric, non-woven fabric, or glass fiber mat) as an intermediary between the metal sheet and the cementitious adhesive. This textile layer acts as a buffer that absorbs level differences and provides a suitable bonding surface for traditional adhesives, enabling simple installation methods while maintaining precision requirements.
3Weight of moving object
If lightweight panels with metal sheets are used to reduce weight, then the weight and logistics are improved, but the compatibility with traditional adhesives deteriorates
Solution Approach 1:
The textile layer serves as a mediator that bridges the incompatibility between the metal sheet and traditional cementitious adhesives. It provides a surface that traditional adhesives can bond to effectively while maintaining the lightweight construction benefits, thus improving both weight reduction and adhesive compatibility simultaneously.
4Strength
If structural adhesives are used for gluing panels, then the bonding strength is improved, but the solidification time and repositioning capability deteriorate
Solution Approach 1:
The textile layer enables the use of traditional cementitious adhesives instead of structural adhesives. These traditional adhesives have longer working times and allow for repositioning during installation, while the textile layer ensures sufficient bonding strength is achieved through proper adhesive distribution and bonding surface preparation.
Data Source
AI summary
A multi-layer panel (10; 20) is described comprising, in sequence, a decorative slab (11) made of natural stone or Ultra High Performance Concrete, a structural central layer (12), a metal sheet (13) and a textile layer (14) made of fabric, non-woven fabric, or of a glass fiber mat. The textile layer makes direct gluing of the panel possible with cementitious adhesives used in construction. The panel can be produced in large format slabs, not achievable with the panels currently on the market.