Field of the invention

[0001] The present invention generally finds application in the field of composite materials, particularly for use in the building and furnishing industries, and particularly relates to a method of making a multilayer panel made of composite material

Background art

[0002] Multilayer panel made of composite materials have been long known to be used as internal and external cladding of surface walls in the building and furnishing industries.

[0003] Such panels typically comprise at least one stone slab of predetermined thickness, which is bonded to at least one reinforcement element adapted to impart strength to the slab while maintaining a low weight thereof.

[0004] Preferably, the reinforcement element comprises a metal or synthetic central core having a three-dimensional structure, e.g. a honeycomb structure, composed of cells and a pair of lattice sheets, adapted to be bonded to the flat surfaces of the core.

[0005] The reinforcement element is bonded to the slab at one of the sheets with one of the free surfaces of the slab.

[0006] Of course, the operator purchases the finished reinforcement element available on the market and later bonds it to the slab.

[0007] A first drawback of this arrangement is that the sheets of the reinforcement element must conform with the plan shape of the central core and are not easily adapted to the surface of the slab on which they have to be bonded, especially if the latter has projections and irregularities. This will result in imperfect adhesion of the reinforcement element to the slab, and will involve the risk that the latter may separate when the panel has been mounted.

[0008] A further drawback is that finished reinforcement elements are quite expensive and will add to the overall cost of the finished panel. [0009] In an attempt to at least partially obviate these drawbacks, methods have been provided to make multilayer panels in which the reinforcement element is directly formed on the slab during assembly of the panel.

[0010] IT1 385520 discloses a method of making multilayer panels as described hereinabove, which comprises a first step of providing a stone slab and a step of laying a fiberglass sheet on one of the faces of the slab with the interposition of a resin.

[0011 ] Then, a reinforcement element with a central core having a surface covered with an additional fiberglass sheet and a free surface is bonded to the first fiberglass sheet and then to the slab

using the previously laid resin.

[0012] In order to facilitate adhesion of the various components, the panel so formed is first introduced into a hermetically sealed plastic bag to create vacuum and then in a furnace for the resin to be cured by heating.

[0013] A first drawback of this prior art arrangement is that the reinforcement element in use is purchased in an almost entirely finished form, and cannot obviate the aforementioned drawbacks.

[0014] Furthermore, the method has no intermediate step for promoting adhesion between the parts of the reinforcement element, the sheets and the slab, which will maintain a high risk of separation thereof after assembly.

[0015] A further drawback is that the plant for carrying out the present method is required to comprise a furnace for heating and curing the resin, which will add to the overall manufacturing costs.

Technical Problem

[0016] In light of the prior art, the technical problem addressed by the invention may be deemed to consist in providing a method of making a multilayer panel that can improve adhesion of the reinforcement element with the sheet mats and the slab, thereby reducing the overall manufacturing costs.

Summary of the invention

[0017] The object of the present invention is to solve the above mentioned technical problem and obviate the above discussed drawback, by providing a method of making a multilayer panel made of composite material that is highly efficient and relatively cost-effective.

[0018] A particular object of the present invention is to provide a method of making a multilayer panel made of composite material that improves adhesion of the reinforcement element to the stone slab.

[0019] Another object of the present invention is to provide a method of making a multilayer panel made of composite material that has a particularly low cost.

[0020] A further object of the present invention is to provide a method of making a multilayer panel made of composite material that is particularly simple.

[0021 ] Yet another object of the present invention is to provide a method as described above that allow the panel to be formed through a small number of steps.

[0022] These and other objects, as better explained below, are fulfilled by a method of making a multilayer panel made of composite material as defined in claim 1 and comprising an intermediate step and a final step in which vacuum is created on the reinforcement element and the panel respectively.

[0023] By this arrangement, a multilayer panel made of composite material may be formed, in which the parts are optimally bonded together. Furthermore, the method has the advantage of being particularly simple and of reducing the overall manufacturing costs for the panel.

[0024] In a preferred embodiment, all the method steps are carried out at ambient temperature and at a substantially constant pressure.

[0025] Furthermore, the permanence times of the various multilayer assemblies have a substantially equal average duration, ranging from 8 h to 1 5 h, about 1 2 h.

[0026] Conveniently, the adhesive resin is selected from the group comprising two-component epoxy resins.

[0027] Advantageous embodiments of the invention are obtained in accordance with the dependent claims. Brief description of the drawings

[0028] Further characteristics and advantages of the invention will be more apparent from the detailed description of a preferred, non-exclusive embodiment of a method of making a multilayer panel made of composit material of the invention, which is described

as a non-limiting example with the help of the annexed drawings, in

which:

FIG. 1 is a block diagram of a first embodiment of the method of the invention;

FIG. 2 is a block diagram of a second embodiment of the method of the invention;

FIGS 3a to 3i are broken-away lateral views which depict the steps of the method of making a multilayer panel according to a first embodiment;

FIG. 4 is an exploded perspective view of a first embodiment of a multilayer panel made of composite material;

FIG. 5 is a broken-away lateral view of a second embodiment of a multilayer panel obtained with the method of the invention.

Detailed description of a preferred exemplary embodiment

[0029] Referring to the figures, particularly FIGS. 1 and 2 show a method of making a multilayer panel made of composite material, which is suitable for use, preferably but without limitation, in the building and furnishing industries, not only for ground-based constructions, but also for nautical and aeronautical engineering.

[0030] As best shown in FIGS. 3i, 4 and 5, the multilayer panel made of composite material obtained with the method of the invention, generally designated by numeral 1 , comprises at least one slab 2 made of an inert material, preferably a stone material such as marble or the like, and at least one reinforcement layer 3, preferably having a three-dimensional structure, preferably a honeycomb structure, which is bonded to the slab 2.

[0031 ] The panel 1 may be used as cladding or flooring for walls and surfaces, for residential, industrial or marine applications, e.g. for interior furnishings of yachts, and may be attached to respective surfaces by appropriate high-strength adhesives or mechanical fastener means.

[0032] The peculiar feature of the panel 1 is that the reinforcement element 3 imparts high mechanical strength to the slab 2, thereby preventing breaking or detachment thereof, and allowing the panel 1 to have a very light-weight structure.

[0033] According to a preferred embodiment, as shown in the block diagram of FIG. 1 and in FIGS. 3A-3i, the method comprises a step of a) providing a first sheet-like fiberglass mat 4 and laying it on a first support plan Pi .

[0034] The first mat 4 may be also made of a material that is similar to but other than fiberglass, such as aluminum or steel, and has a predetermined plan shape.

[0035] Furthermore, the first mat 4 is initially rolled up and the operator in charge of making the panel 1 will have to unroll it above the support plan Pi and cut a portion of desired size therefrom.

[0036] The operator shall lay the first mat 4 on the support plan P while avoiding the formation of wrinkles or gathers thereof, which might affect the later steps of forming the panel 1 .

[0037] Then, a second step is provided of b) laying a first layer of adhesive resin 5 on the top face 6 of the first mat 4, i.e. the face that does not contact the support plan P-i , as shown in Fig. 3b.

[0038] The adhesive resin 5 may be selected from the group comprising two-component epoxy resins and will be laid upon the first mat 4 until the latter is entirely impregnated therewith.

[0039] The method comprises a step of c) providing a three-dimensional honeycomb reinforcement element 3 whose plan size is slightly smaller than the first mat 4, as shown in FIG. 3c.

[0040] The reinforcement element 3 substantially corresponds to the metal core of common available honeycomb panels.

[0041 ] The reinforcement element 3 is laid over the first mat 4 until it is at least partially embedded in the first layer of adhesive resin 5 and forms therewith a first assembly 7 with a free upper face 8. [0042] The step c) is followed by a step of d) overlaying the first assembly 7 with an impermeable sheet T sealingly lying over the first support plan P and defining a watertight cavity C, as shown in FIG. 3d.

[0043] The sheet T is mounted to a support B which is adapted to lie over the first assembly 7 and comprises a top opening A whose purpose will be better explained hereinafter.

[0044] A step will follow, of e) connecting the cavity C that contains the first assembly 7 to a vacuum source for a first predetermined time interval to promote adhesion of the reinforcement element 3 to the first mat 4, as shown in FIG. 3d.

[0045] Advantageously, the vacuum source may comprise a suction pump and the cavity C may be connected thereto through the top opening A formed on the support B.

[0046] The support B with the impermeable sheet T may be used with different types of support surfaces without altering the desired vacuum conditions and may have standard sizes, allowing it to overlap reinforcement elements 3 of different sizes.

[0047] Furthermore, this arrangement allows the operator to create vacuum by directly acting on the support plan P-i , without moving the reinforcement element 1 being processed.

[0048] Meanwhile, a step is carried out of f) providing a stone slab 2 whose size substantially corresponds to that of the first assembly 7 and laying it over a second support plan P ₂ , as clearly shown in FIG. 3e.

[0049] Possibly, prior to the step of f) providing the slab 2 on the second support plan P ₂ , a step may be envisaged of I) leveling and reducing the surface ruggedness of the face 1 0 of the slab 2, for improved adhesion of the second mat 9.

[0050] A step is also provided, as shown in FIG. 3f, of g) providing a second mat 9 and laying it over the slab 2, particularly over the free face 10 of the latter, which does not contact the second support plan P ₂ .

[0051 ] The second mat 9, like the first mat, is made of fiberglass and has substantially the same size as the stone slab 2. [0052] According to an alternative embodiment of the invention, the two mats 4, 9 may be also made of different materials without altering the structure of the finished multilayer panel 1 .

[0053] Prior to the step g) a step may be provided of m) washing the free face 1 0 of the slab 2 with a high-pressure waterjet treatment machine using a high-pressure pump, not shown. Namely, this machine is connected to a pump having a pressure of about 2000 bar.

[0054] Similar to what has been discussed above, a step is later provided, as shown in FIG. 3g, of h) laying a second layer of adhesive resin 1 1 on the second mat 9 to impregnate it and promote its adhesion to the slab 2 to define a second assembly 1 2.

[0055] The resin 1 1 that is used for bonding the second mt 9 may also be selected from the group comprising two-component epoxy resins.

[0056] Advantageously, as the second mat 9 is laid on the free face 1 0 of the slab 2, the surface of the latter may be leveled and its ruggedness may be substantially smoothened out.

[0057] Finally, the above discussed washing step m) can remove dust from the free face 10 of the slab 2 and create surface loops thereon to increase the adhesion surface with the second resin layer 1 1 laid during the step h).

[0058] Once the support B has been removed from the first working plan P-i , a step is provided of i) turning the first assembly 7 upside down and laying it on the second assembly 1 2, as shown in FIG. 3h.

[0059] The first assembly 7 is laid over the second assembly 1 2 with its free face 8 at least partially embedded in the second layer of adhesive resin 1 1 to obtain a third assembly 1 3.

[0060] Advantageously, the use of the second resin layer 1 1 to bond both the second mat 9 to the slab 2 and the first assembly 7 to the second assembly 1 2 can reduce the total amount of resin required to form the panel 1 and the overall time for making it.

[0061 ] The method comprises a step of j) overlaying the third assembly 1 3 with an impermeable sheet T sealingly lying over the second support plan P ₂ and defining a cavity C. [0062] A step will follow, of k) connecting the cavity C that contains the third assembly 1 3 to a vacuum source for a second predetermined time interval to promote adhesion of the reinforcement element 3 to the first mat 4 and the second mat 9 and obtain a finished multilayer panel 1 , as shown in FIG. 3i.

[0063] Similar to step d), the impermeable sheet T is mounted to a rigid support B having a top opening A for connection of the cavity C with the vacuum source.

[0064] Steps a) to k) may be carried out at ambient temperature and steps e) and k) may have a substantially equal average duration, ranging from 8h to 1 5h, substantially close to 12h.

[0065] Thus, adhesion of the reinforcement element 3 to the slab 2 is only improved by creating vacuum, without changing the temperature of the adhesive resin.

[0066] Also, the possibility of avoiding the use of a device for heating the panel 1 and drying the resin greatly simplifies the method and reduces its overall implementation costs.

[0067] Furthermore, the steps e) and k) of creating vacuum on the first assembly 7 and the third assembly 1 3 respectively within the cavity C may be carried out at a constant pressure, substantially close to 0.6 bar.

[0068] In a further embodiment of the invention, as shown in the block diagram of FIG. 2, the method may comprise, prior to the step of k) creating vacuum, a step of n)providing a third sheet-like fiberglass mat 14 of substantially the same size as the slab 2.

[0069] Also, the step n) includes lying a third layer of adhesive resin 15 on the third mat 14 and is followed by a step of o) overlying the third layer of resin 1 5 with a second honeycomb reinforcement element 1 6 to obtain a fourth assembly 1 7.

[0070] Then, the support B with the sheet T is laid over the fourth assembly 1 7 to define the cavity C and is connected to the vacuum source, similar to what has been discussed above for the previous steps e) and k), for a third predetermined time interval, to facilitate adhesion between the third mat 14 and the second honeycomb reinforcement element 1 6.

[0071 ] A step is further provided of p) providing a fourth fiberglass mat 18 of substantially the same size as the slab 2 and a step is provided of laying the fourth mat 1 8 on the free face 1 9 of the slab 2 of the third assembly 13 obtained in the step i) of the original method.

[0072] The step q) is followed by a step of r) laying a fourth layer of adhesive layer 20 on the fourth mat 1 8 to impregnate it and promote bonding thereof to the slab 2, and by a step of s) laying the second honeycomb element 1 6 on the fourth mat 1 8 to promote bonding of the slab 2 of the intermediate panel 21 , as shown in FIG. 5.

[0073] Finally, the method may include, downstream from the step k), a step of t) detaching the slab 2 of the intermediate panel 21 to obtain a pair of half-panels 1 ', not shown, each with a half-plate 2' having half the thickness of the slab 2 and with a corresponding reinforcement element 3, 1 6.

[0074] In both embodiments of the method, the stone slabs and the reinforcement elements may have different shapes, sizes and thicknesses.

[0075] Advantageously, in one embodiment, not shown, the reinforcement element 3 may comprise holes located in predetermined positions for receiving respective bushings.

[0076] The bushings will be adapted to support means for hanging the multilayer panel 1 on a wall. Particularly, the hanging means may comprise a plurality of brackets with respective grooves, and a plurality of metal profiles affixed to the wall and having respective mating grooves for receiving and engaging the brackets.

[0077] In an alternative embodiment of the invention, also not shown, the holes for receiving the bushings may be formed in the slab 2.

[0078] All the details thereof may be replaced by other technically equivalent parts, and the materials may vary depending on different needs, without departure from the scope of the invention.

[0079] While the method has been described with particular reference to the accompanying figures, the numerals referred to in the disclosure and claims are only used for the sake of a better intelligibility of the invention and shall not be intended to limit the claimed scope in any manner.

Industrial Applicability

[0080] The present invention may find application in industry, because it can be produced on an industrial scale in factories in the field of stone slab processing, particularly for the building and furnishing industries.