PORCELAIN LAMINATE AND PROCEDURE FOR MANUFACTURING IT

Abstract

The laminate comprises a porcelain sheet with a thickness of two to three millimetres, adhered to a base or support sheet made of MDF or particleboard or high density foam or polyethylene or polypropylene or ABS or foamed PVC or methacrylate or a metal sheet of aluminium or steel, using as the adhesion means a two-component polyurethane or a PUR adhesive, producing a laminate that encompasses the advantages of the nature of the two materials, the porcelain and the base, as well as saving material, and being lighter, having higher thermal and acoustic insulation levels, improved resistance to bending loads and allowing to add additional layers, such as a metal sheet of thickness from 0.1 to 1 mm in order to obtain a greater flatness, or a combination with rubber or elastomer layers to improve the acoustic insulation level.

Claims

1. Procedure for manufacturing a porcelain laminate comprising: a sheet of porcelain stoneware with thickness from 2 to 7 mm adhered to a sheet that acts as a base or support; wherein the procedure comprises the following stages: Cleaning the face of the porcelain stoneware that will be adhered to the base or support sheet by blowing, cleaning brushes and suction; Pre-treating the base or support sheet, in a manner depending on its composition: Applying to the face of the base or support sheet a two-component polyurethane adhesive or a PUR adhesive; Adhering the porcelain stoneware sheet to the base or support sheet by gradually applying pressure; Allowing the laminate assembly to rest for 3 or 4 days, preferably under pressure, using for example a metal bench or plate with the same dimensions as the laminate obtained.

2. Procedure for manufacturing the porcelain laminate according to claim 1, characterised in that if a polyethylene sheet is used as the base sheet, the face of the base or support sheet to be glued can receive the following treatment: Crowning; Trimming.

3. Procedure for manufacturing the porcelain laminate according to claim 1, characterised in that the gradual pressure to apply to glue the two sheets depends on the composition of the base or support sheet: If the base or support sheet is made of polyethylene, the pressure to apply is on the order of 15 to 20 Kg/cm2; If the base or support sheet is made of rubber, the pressure to apply is on the order of 30 Kg/cm2; If the base or support sheet is made of high density foam, the pressure to apply is on the order of 5 to 7 Kg/cm2; If the base or support sheet is made of methacrylate, the pressure to apply is on the order of 15 to 20 Kg/cm2; If the base or support sheet is made of MDF wood, the pressure to apply is on the order of 15 to 25 Kg/cm2.

4. Procedure for manufacturing the porcelain laminate according to claim 1, characterised in that if it has a metal sheet adhered to the base or support sheet, or if the support sheet is a metal sheet, the metal sheet is subjected to the following procedure in order to adhere it: Scraping the metal sheets to a depth of 60 to 120 microns, uni-directionally in a longitudinal sense, so that in addition to cleaning grease, oil and dirt from the surface of the face that will be attached to the central core, one of the faces of the metal sheet is given a certain roughness. Scraping is performed with a grain size suitable for metal sheets. Applying a primer, a paint that attaches well to the metal, sealing it to prevent rusting and preparing the surface for the subsequent application of an adhesive. The primer must be a paint particularly suitable for adherence to the plastic materials and the adhesives used subsequently, both for two-component polyurethane and for reactive polyurethane adhesives. Drying the primer in an oven at a temperature from 60-180 C. Applying a special outdoor adhesive that can be of different types, including reactive polyurethane and two-component polyurethane adhesives. The adhesive can be applied: With a roller; Spraying it on; With a pistol, applying lines or beads in a spiral form.

5. Procedure for manufacturing the porcelain laminate according to claim 1, characterised in that if the material used in the laminate employed as support is MDF, particleboard, high density foam, polyethylene or polypropylene, methacrylate, high pressure laminate or plywood, once the laminate or assembly is conformed it is adhered directly to the porcelain sheet.

6. Procedure for manufacturing the porcelain laminate according to claim 1, characterised in that if the core of the support laminate is made of a silicate or fibre cement, the process is as follows: Adhering a metal sheet to the back face of the porcelain panel; Then, adhering the silicate or fibre cement sheet; Finally, adhering another metal sheet.

7. Procedure for manufacturing the porcelain laminate according to claim 2, characterised in that if it has a metal sheet adhered to the base or support sheet, or if the support sheet is a metal sheet, the metal sheet is subjected to the following procedure in order to adhere it: Scraping the metal sheets to a depth of 60 to 120 microns, uni-directionally in a longitudinal sense, so that in addition to cleaning grease, oil and dirt from the surface of the face that will be attached to the central core, one of the faces of the metal sheet is given a certain roughness. Scraping is performed with a grain size suitable for metal sheets. Applying a primer, a paint that attaches well to the metal, sealing it to prevent rusting and preparing the surface for the subsequent application of an adhesive. The primer must be a paint particularly suitable for adherence to the plastic materials and the adhesives used subsequently, both for two-component polyurethane and for reactive polyurethane adhesives. Drying the primer in an oven at a temperature from 60-180 C. Applying a special outdoor adhesive that can be of different types, including reactive polyurethane and two-component polyurethane adhesives. The adhesive can be applied: With a roller; Spraying it on; With a pistol, applying lines or beads in a spiral form.

8. Procedure for manufacturing the porcelain laminate according to claim 3, characterised in that if it has a metal sheet adhered to the base or support sheet, or if the support sheet is a metal sheet, the metal sheet is subjected to the following procedure in order to adhere it: Scraping the metal sheets to a depth of 60 to 120 microns, uni-directionally in a longitudinal sense, so that in addition to cleaning grease, oil and dirt from the surface of the face that will be attached to the central core, one of the faces of the metal sheet is given a certain roughness. Scraping is performed with a grain size suitable for metal sheets. Applying a primer, a paint that attaches well to the metal, sealing it to prevent rusting and preparing the surface for the subsequent application of an adhesive. The primer must be a paint particularly suitable for adherence to the plastic materials and the adhesives used subsequently, both for two-component polyurethane and for reactive polyurethane adhesives. Drying the primer in an oven at a temperature from 60-180 C. Applying a special outdoor adhesive that can be of different types, including reactive polyurethane and two-component polyurethane adhesives. The adhesive can be applied: With a roller; Spraying it on; With a pistol, applying lines or beads in a spiral form.

Description

DESCRIPTION OF THE DRAWINGS

[0082] To complete the description made below and to aid a better understanding of its characteristics, the present descriptive memory is accompanied by a set of drawings, the figures of which represent the most significant details of the invention for purposes of illustration only and in a non-limiting sense.

[0083] FIG. 1 shows a cross-section view of the laminate object of the invention.

[0084] FIG. 2 shows a cross section of a mode of execution in which, in addition to the sheets shown in FIG. 1, there is a metal counterface or sheet adhered to the free face of the base or support sheet.

[0085] FIG. 3 shows a schematic view of the various stages of the manufacturing process.

[0086] FIG. 4 to FIG. 7 show different embodiments of the laminate.

PREFERRED EMBODIMENT OF THE INVENTION

[0087] In view of the figures, a preferred embodiment of the proposed invention is described below.

[0088] FIG. 1 shows the basic and essential configuration of the laminate object of the invention, which comprises a porcelain sheet (1) with a small thickness of less than about 7 mm. This value should not be understood in a limiting sense, and is simply meant to illustrate the small thickness of the porcelain sheet; a reasonable thickness will be from 2 to 7 mm. This porcelain sheet (1) is adhered to a base or support sheet (2) that can have any composition, preferably one of the following or a combination thereof: [0089] MDF (Medium Density Fibreboard); [0090] Particleboard; [0091] High density foam; [0092] Polyethylene, polypropylene, ABS or foamed PVC; Methacrylate; [0093] HPL (High-Pressure Laminate) compact; [0094] Plywood boards; [0095] Aluminium or steel plate.

[0096] With this configuration, and as previously described, a synergic effect is obtained between the properties of the porcelain sheet (1) and those of the support sheet (2), defining a laminate with a great resistance to abrasion, wear, attack by chemical agents, as well as having an outstanding aesthetic result, while being lighter than a porcelain plate as used to date, increasing its bending resistance, increasing its acoustic insulation properties and being less expensive, as well as easier to machine.

[0097] Due to the aforementioned properties it has many applications, ranging from cladding partitions, facades, raised floors or for building ships, train cars, aircrafts, etc.

[0098] FIG. 2 shows an embodiment that complements the previous one, consisting of manufacturing a laminate which, in addition to the porcelain sheet (1) and the base or support sheet (2), has a metal sheet or metal counterface (3) with a small thickness, from 0.1 to 1 mm, these values being meant by way of orientation and example to show that the metal sheet has a small thickness.

[0099] This metal sheet (3) is used to maintain the flatness of the laminates manufactured. The material used to manufacture the metal sheet (3) or metal counterface (3) is preferably aluminium, steel or stainless steel. The composition of the metal sheet used is also not limiting.

[0100] The procedure used to adhere the porcelain sheet (1) to the base or support sheet (2) is as described above, while that used to adhere the base or support sheet (2) to the metal sheet (3) has also been described in the description of the invention.

[0101] FIG. 3 shows the different stages required to adhere the porcelain sheet (1) and the base or support sheet (2). These stages are the following: [0102] a) Cleaning (4) the face of the porcelain stoneware that will be adhered to the base or support sheet by blowing, cleaning brushes and suction; [0103] b) Pre-treating (5) the base or support sheet according to its composition; [0104] c) Applying (6) to the face of the base or support sheet a two-component polyurethane adhesive or a PUR adhesive; [0105] d) Adhering (7) the porcelain sheet to the base or support sheet by gradually applying pressure. [0106] The rollers used to apply the pressure on the porcelain sheet have a hardness of 60, to avoid damaging the porcelain stoneware; [0107] e) Allowing the laminate assembly to rest (8) for 3 or 4 days, preferably under pressure, using for example a metal bench or plate with the same dimensions as the laminate obtained.

[0108] If a polyethylene sheet is used as the base sheet, the face of the base or support sheet to be adhered can receive the following pre-treatment: [0109] Crowning; [0110] Trimming.

[0111] In FIG. 4, it can be observed that a foam sheet (4) and a second metal sheet (5) are adhered to the above-described assembly formed by the porcelain stoneware (1), the base support sheet (2), and the metal sheet or metal counterface (3).

[0112] In FIG. 5, it is shown how the base or support sheet consists of a laminate with a core (6) that can be made of any of the aforementioned materials (MDF, particleboard, foams, polyethylene, methacrylate, HPL or plywood) and that is laminated on both faces with corresponding metal sheets (7), wherein the thickness of the metal sheets of either face of the core do not have to be the same.

[0113] In FIG. 6, it is observed that the base support sheet is a laminate formed by a sheet of silicates or fibre cement (8) having metal laminate (9) in at least one of the faces.

[0114] In FIG. 7, it is observed that the base or support sheet is made of one of the materials (MDF, particleboard, foams, polyethylene, methacrylate, high pressure laminate or plywood) (10) and has an additional sheet or counterface (11) made of porcelain stoneware or silica quartz.

[0115] The essence of this invention is not affected by variations in the materials, shape, size and arrangement of its component elements, described in a non-limiting manner that will allow its reproduction by an expert.