Composite stone panels

Abstract

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.

What is claimed is: 
     
         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.