COMPOSITE STONE PANELS
A composite stone panel can comprise a stone slab. A partially metallic panel backer is coupled to the stone slab and can further comprise a core material layer, a first interface layer disposed on a first surface of the core material layer, and a second interface layer disposed on a second surface of the core material layer opposite the first metal interface layer. The stone slab can further comprise a length greater than 1.2 meters (m), a width greater than 0.6 m, and a thickness in a range of 0.2-1.5 centimeters (cm). The core material layer can comprise a thickness greater than 3.75 millimeters and can further comprise polyethylene and optional fibers. The first and second interface layers can comprise a thickness of aluminum in a range of 0.21 millimeters (mm) to 0.30 mm. Accordingly, the composite stone panel can comprises a thickness in a range of 0.6-3.0 cm.
1 . A composite stone panel, comprising:
a stone slab; and
a partially metallic panel backer coupled to the stone slab, further comprising:
a core material layer,
a first interface layer disposed on a first surface of the core material layer, and
a second interface layer disposed on a second surface of the core material layer opposite the first metal interface layer.
2 . The composite stone panel of claim 1 , wherein the stone slab further comprises a length greater than 1.2 meters (m), a width greater than 0.6 m, and the composite stone panel comprises a thickness in a range of 0.6-3.0 centimeters.
3 . The composite stone panel of claim 1 , wherein the core material layer comprises a thickness greater than 3.75 millimeters and further comprises polyethylene with optional fibers.
4 . The composite stone panel of claim 1 , wherein the first and second interface layers comprise a metal.
5 . The composite stone panel of claim 4 , wherein the first and second interface layers comprise a thickness of aluminum or aluminum alloy in a range of 0.21 millimeters (mm) to 0.30 mm.
6 . The composite stone panel of claim 4 , wherein:
the first and second interface layers comprise a coefficient of thermal expansion in a range of 20-30; and
the core material layer comprises a coefficient of thermal expansion in a range of 20-200.
7 . The composite stone panel of claim 4 , wherein the first interface layer and second interface layer comprise dimples that increase the surface area of the metal backer by a factor of about two.
8 . The composite stone panel of claim 1 , wherein the partially metallic panel backer further comprises a honeycomb metallic core and fiberglass first and second interface layers.
9 . A composite stone panel, comprising:
a stone slab comprises a length greater than 1.2 meters (m), a width greater than 0.6 m, and a thickness in a range of 0.2-1.5 centimeters (cm); and
a panel backer coupled to the stone slab, further comprising:
a core material layer,
a first interface layer disposed on a first surface of the core material layer, and
a second interface layer disposed on a second surface of the core material layer opposite the first metal interface layer.
10 . The composite stone panel of claim 9 , wherein the composite stone panel further comprises a thickness in a range of 0.6-3.0 cm.
11 . The composite stone panel of claim 9 , wherein the core material layer comprises a thickness greater than 3.75 millimeters and further comprises polyethylene.
12 . The composite stone panel of claim 9 , wherein the first and second interface layers comprise a metal comprising a thickness in a range of 0.21-0.30 millimeters (mm).
13 . The composite stone panel of claim 12 , wherein the metal first or second interface layer comprises dimples.
14 . The composite stone panel of claim 9 , wherein the partially metallic panel backer is coupled to the stone slab with a thickness of epoxy adhesive in a range of 0.2-1.5 millimeters (mm).
15 . The composite stone panel of claim 9 , wherein the partially metallic panel backer further comprises a honeycomb metallic core and fiberglass first and second interface layers.
16 . A method of making composite stone panels, comprising:
cutting a stone slab to comprise a length greater than 1.2 meters (m), a width greater than 0.6 m, and a thickness in a range of 0.2-1.5 centimeters (cm);
attaching first and second panel backers to first and second opposing surface of the stone slab; and
cutting the stone slab between the first and second panel backers to form first and second composite stone panels.
17 . The method of claim 16 , further comprising forming the first and second panel backers comprising a core material layer and first and second interface layers disposed on first and second opposing surfaces of the core material layer.
18 . The method of claim 17 , further comprising:
forming the core material layer comprising a thickness greater than 3.75 millimeters (mm) and further comprising polyethylene with optional fibers; and
forming the first and second interface layers comprising a thickness of aluminum in a range of 0.21-0.30 mm.
19 . The method of claim 16 , further including forming dimples in a surface of the first or second panel backers.
20 . The method of claim 17 , further including:
forming the first and second interface layers comprising a coefficient of thermal expansion in a range of 20-30; and
forming the core material layer comprising a coefficient of thermal expansion in a range of 20-200.