BE1024001B1 - Prefabricated wall panel - Google Patents

Abstract

This invention relates to a prefabricated panel for constructing or cladding a wall, the prefabricated panel including a load-bearing panel, one side of the load-bearing panel being coated with a plurality of stones which are attached to the panel with an adhesive to be. A two-component polyurethane adhesive is used as the adhesive.

Description

Prefabricated wall panel.

This owl invention relates to a prefabricated panel according to the preamble of the first claim.

It is known to cover the facade of a building with panels made of an insulating material such as a panel in glass wool or EPS (expanded polystyrene), the panels resting on one side against a frame placed against a building. After the panels are attached to the frame, the finishing materials such as natural stone, artificial stone or bricks are applied to the other side of the panels. However, this method is time-consuming and can only be carried out directly on an existing wall of a building. EP-Al-238,191 describes a brick panel which is attached to an insulating wall panel by means of a fixing means and forms a whole with it, as well as a method for manufacturing it. The wall panel can for instance be made of EPS, polyurethane, vermiculite, phenolic resin, PVC, PE or PP. The finishing material can be, for example, a natural stone, an artificial stone, an inorganic panel, a ceramic tile or an aluminum panel or brick. According to the method described in EP-Al-238,191 a finishing material and an underlying insulation panel are cut to the desired size, the insulation panel is coated with an adhesive, after which the finishing material is applied to the adhesive and the adhesive is allowed to cure around the insulation panel and the to connect finishing material. To achieve good adhesion, the insulating wall panel and the finishing material are pressed together. However, this requires a special pressing device and an additional process step and imposes limitations on the product in terms of dimensions and shape.

Prefabricated panels and methods for manufacturing them are also known. EP-A2-1.726.731 describes a prefabricated panel with a rectangular shape for constructing walls, the panel comprising a base layer made of cement or resin on which an upper visible layer of bricks or the like is applied. The resin or cement function as an adhesive for the stones. Such panels are manufactured using a mold that has the shape of the panel. The prefabricated panels known from EP-A2-1.726.731, however, have the disadvantage that by using a mold only panels of a predetermined shape and dimensions can be made, and that the options for arranging the stones are limited. Attaching the panel to a wall can also be complicated and must be done by bonding the panel via the base layer.

The object of the present invention is to provide a solution for the disadvantages described above. In particular, it is an object of the present invention to provide a prefabricated panel and a method for producing it, wherein the dimensions of the panel can be chosen at random taking into account the intended application and a wide range of possibilities can be offered for arranging the bricks. on the panel. DE102012110002 describes a wall or floor covering element that can be easily applied and removed, and which can be used, for example, as a room screen for dividing a room into individual rooms. To this end, the covering element is made up of a support plate, with a front side on which tiles, clinkers or the like are glued as a covering. DE2718397 describes to coat one side of a carrier, for example a wooden plate, with a glued foam for absorbing stresses, to which subsequently coating plates are attached using a polyurethane resin. WO2004 / 076774 describes a wall element that is built up from a profiled metal or plastic plate, on which there is a layer of small stones embedded in a resin. EP676427 describes two component polyurethane adhesives, consisting of (A) a polyisocyanate component with an NCO content between 10 and 25 wt. %, a maximum viscosity of 2,500 mPa.s (25 ° C) and an average functionality between 2 and 3, (B) i) at least one aliphatic diol with an OH number of at least 835 mg KOH / g, ii) at least one polyol with an OH number between 20 and 200 mg KOH / g and an average functionality between 2 and 4, iii) at least one aliphatic or aromatic di- or trifunctional amine with a maximum molecular weight of 300 g / mol, where component (B ) has an average OH number of 200 to 290 mg and a viscosity of at least 3,000 mPa.s (25 ° C), and (C) 0.005 to 2.0 wt. % 1 of a catalyst for the reaction between components A and B.

EP481,319 discloses polyurethanes suitable for use as stable two-component polyurethane adhesives which contain high-molecular polyhydroxyl compounds and short-chain polyols. WO98 / 10030 describes a self-supporting element consisting of bricks, porous concrete, Ytong blocks, or other building blocks that are connected to each other by means of polyurethane glue. The structure is self-supporting and can be a vertical structure such as a wall or a horizontal structure such as a floor. To facilitate penetration of the glue into the surface of the stones, the glue preferably contains a plasticizer.

This is achieved according to the present invention with a panel which has the technical features of the feature of the first claim.

To this end, the panel of the present invention is characterized in that a two-component polyurethane adhesive is used as the wetting agent.

The two-component polyurethane adhesive consists of a first and a second component, which react upon contact with each other, the first component containing a diisocyanate, and the second component containing: 40.0-70.0 wt. % of one or more polyols, in particular one or more polyether polyols, one or more polyester polyols, one or more polyether polyester polyols or a mixture of two or more of the aforementioned polyols and a maximum of 0.15 wt. %, preferably a maximum of 0.10 wt. % of a catalyst to catalyze the reaction between the first and the second component.

The second component further contains 0.5-2.5 wt. % of one or more amines, the amine containing at least one active H group capable of reacting with an isocyanate. At a concentration lower than 0.5 wt. % there is a risk of the glue flowing out, as a result of which a layer thickness that is too low can occur and a scratch strength that is too small. With a concentration of more than 2.5 wt. % there is a risk that the adhesive becomes too thick, that the number of remaining free OH groups becomes too low, and suboptimal curing of the adhesive is achieved after the urethane reaction.

Within the scope of this invention, the catalysts known to those skilled in the art can be used, including metallic compounds based on lead, tin, bismuth or zinc. Because mercury carboxylates are toxic, notwithstanding their high selectivity for the polyol isocyanate reaction, an alkyl tin carboxylate is preferably used. A suitable example is dibutyl tin laurate.

The second component of the adhesive of this invention ordered one or more polyols. Preferably a polyol is used which has a molecular weight (in g / mole) of at most 6000, preferably between 250 and 5000, more preferably buses 250 and 2000, most preferably between 500 and 1500. The polyols used in this invention preferably have an OH number of at most 1500, more preferably between 50 and 1250, most preferably between 100 and 500, in particular between 200 and 500.

Polyols suitable for use in this invention include polyether polyols, polyester polyols and / or polyether polyester polyols. Polyols suitable for use in this invention are both diols and triols and compounds with more than 3 OH groups in the molecule, but preferably one or more triols are used. This solves the problem that the amount required of the first component can be kept within reasonable limits.

The use of one or more polyether polyols in the second component is preferred because of their cost and availability. However, if a particular reactivity is envisaged, and / or the hydrophilic / lipophilic balance of the adhesive is intended to be influenced, a polyester polyol or a polyester polyether polyol copolymer can be chosen. However, within the scope of this invention, it is also possible to use blends of two or more of the aforementioned polyols.

The polyether polyol used in this invention is preferably selected from the group of poly (alkylene oxide) glycols with an alkylene group containing between 2 and 20 carbon atoms. The polyether subunit preferably contains a polyoxyalkylene polyol with 2 to 6 carbon atoms in the alkylene group. Particularly suitable polyether polyols are those prepared from poly (1,2-propylene oxide) glycol and poly (1,3-propylene oxide) glycol, poly (tetraethylene oxide) glycol, poly (pentamethylene oxide) glycol, poly (hexamethylene oxide) glycol, poly (heptamethylene oxide) glycol, poly (octamethylene oxide) glycol, poly (nonamethylene oxide) glycol, and poly (1,2-butylene oxide) glycol, as well as block copolymers of ethylene oxide and / or 1,2- propylene oxide, and polyformaldehyde acetals prepared by reacting formaldehyde with a glycol, such as pentamethylene glycol or glycol mixtures, for example a mixture of tetramethylene glycol and pentamethylene glycol. Preferably, however, polyether polyols are used prepared from poly (1,2-propylene oxide) glycol and poly (1,3-propylene oxide) glycol.

Other examples of polyols suitable for use in this invention are short chain diols or triols with a molecular weight of up to 250 g / mol or a molecular weight higher than 250 g / mol, which are derived from diols or triols with 2-15 carbon atoms, preferably 2-6 carbon atoms, such as, for example, ethylene glycol, propylene glycol, tetramethylene glycol, isobutylene glyeol, pentamethylene glycol, 2,2-dimethyltrimethylene glycol, hexamethylene glycol, decamethylene glycol, dihydroxycyclohexane, cyclohexanedimethanol, resorcinol, dihydroxynaphthalone, hydrohydroxynaphthalone connections. Suitable bisphenols include bis (p-hydroxyphenyl), bis (p-hydroxyphenyl) methane, bis (p-hydroxyphenyl) propane, and 2,2-bis (p-hydroxyphenyl) propane. Other suitable examples are a glycerol polyethylene glycol triether, a glycerol polypropylene glycol triether, a glycerol polyethylene polypropylene glycol triether, glycerol polystyrene glycol triether, a glycerol polybutylene glycol triether or a mixture of two or more of the aforementioned polyethers.

A second type of polyols suitable for use in this invention are polyester polyols and derivatives thereof. The presence of one or more polyester polyols in the first component is preferred if a high resistance of the adhesive to weathering is intended, and a stronger adhesive. Industrial polyester polyols are usually condensation products of an organic acid or a mixture of two or more organic acids, with an alcohol or a mixture of two or more alcohols. Numerous different industrial polyester polyols are commercially available. Suitable polyester polyols are reaction products of a polyol with aromatic or aliphatic dicarboxylic acids and / or lactone polymers. Typical examples of aromatic acids suitable for preparing a polyester polyol include terephthalic acid, isophthalic acid, phthalic acid, phthalic anhydride, substituted dicarboxylic acids with a benzene ring such as bis (p-carboxyphenylmethane) benzoic acid, p-oxy (p-carboxyphenyl) benzoic acid, etc. It is also possible to use hydroxy acids such as p- (p-hydroxyethoxybenzoic acid) if an aromatic dicarboxylic acid is intended. Aliphatic acids suitable for producing polyester polyols for use in this invention include sebacic acid, adipic acid and glutaric acid. Suitable polyols for forming of a polyester polyol include ethylene glycol, butanediol, neopentyl glycol, hexanediol, propylene glycol, dipropylene glycol, diethylene glycol and cyclohexanedimethanol, as well as the hydroxy compounds described above.

A further type of polyols suitable for use in this invention are polyether polyesters, in particular the reaction products of the polyols described above and aromatic or aliphatic dicarboxylic acids and / or lactone polymers, for example polycaprolactone. Fatty acid esters and partially hydrogenated fatty acid esters, in particular Castor oil and / or derivatives thereof, are particularly suitable.

The choice of the polyol will usually be tailored to the hydrophilic / lipophilic balance of the adhesive. For the manufacture of prefabricated panels with a lower water permeability, an adhesive with a more hydrophobic character will usually be envisaged, and a glycerol polypropylene glycol triether is preferably used.

Furthermore, since the catalyst often exhibits some water sensitivity, the second component usually contains 5.0 -15.0 wt. % of one or more zeolites. The presence of the zeolite lowers the risk of deactivation of the catalyst during storage of the second component and increases the shelf life of the second component. Namely, zeolites adsorb water that could possibly be present in the polyol or other components. Instead of a zeolite, other water-reactive systems, such as silanes, can also be used, but these are more expensive and must be handled with greater caution. In general, the second component of the adhesive will be between 5.0 and 15.0 wt. % of an agent capable of absorbing or adsorbing water.

B

More preferably, the second component of the adhesive contains an amine containing at least one tertiary amine group, preferably at least two tertiary amine groups. More preferably, a tertiary amine is used which contains one or more alkanol groups. Such amines are capable of causing a rapid increase in the viscosity of the mixture and accelerating the urethane reaction when the first and second components are brought into contact with each other. This offers the advantage that a trace or string of the adhesive applied to a surface exhibits good physical stability, a low risk of bleeding and remains at the position where it is applied.

Examples of amines that are particularly suitable for use in this invention include tertiary amines such as N, N, N'-trimethyl-N-hydroxyethyl-bisaminoethyl ether (JEFFCAT ZF-10 Huntsman Corp.), N, N-bis (3 -dimethylaminopropyl) -N-isopropanol amine (JEFFCAT ZR-50 Huntsman Corp.), N- (3-dimethylaminopropyl) -N, N-diisopropanolamine (JEFFCAT DPA Huntsman Corp.), Ν, Ν-dimethylethanolamine (JEFFCAT DMEA Huntsman Corp. ) and 2- (2-dimethylaminoethoxy) ethanol (JEFFCAT ZR-70 Huntsman Corp.). Optionally, a secondary amine may be used such as TEDA (1,4-diazabicyclo [2.2.2] octane, dimethylcyclohexylamine (DMCHA), and dimethylethanolamine (DMEA).

The second component further contains the usual additives. The second component further preferably contains 0.2 - 1.5 wt. % of one or more defoamers to prevent foaming in the second component. This is important in order to be able to provide reproducible mixing of the first and second component, a reproducible adhesive with reproducible adhesion and other relevant properties, since the first and second component are mixed on a volume basis. Conventional defoamers are often based on silicone.

The second component further preferably contains 25.0-55.0 wt. % of one or more inorganic inert fillers. A commonly used filler is calcium carbonate, preferably calcium carbonate coated with an organic, hydrophobic coating, for example, a coating based on a fatty acid, for example stearate, to allow optimum mixing with the polyol and optimum distribution in the final product. Other suitable fillers are sand or silica, for example highly dispersed siliea, fumed silica or other forms of silica.

Within the scope of this invention, a wide range of diisocyanates can be used for the first component, which are well known to those skilled in the art. The first component will usually have an isocyanate functionality of at least 1, preferably at least 2, more preferably from about 2 to about 3.5, most preferably from about 2.5-3. The isocyanate can be aromatic or aliphatic.

Typical examples of aromatic isocyanates suitable for use in this invention include methylene diphenyl diisocyanate (MDI), tetramethylxylylene diisocyanate (TMXDI), toluene diisocyanate (TDI), naphthalene diisocyanate, and isophorone diisocyanate (IPDI ) or a mixture of two or more of these, but preferably methylene diphenyl diisocyanate (MDI) is used.

Typical examples of aliphatic diisocyanates suitable for use in this invention include hexamethylene diisocyanate (HDI), hydrogenated MDI, dodecane diisocyanate and dimeric diisocyanates as well as all polymeric and trimeric isocyanates.

The isocyanate preferably contains diphenylmethylene diisocyanate, tetramethylxylylene diisocyanate, isophorone diisocyanate, toluene diisocyanate, hexamethylene diisocyanate or mixtures of two or more of the aforementioned isocyanants.

Within the scope of this invention, the first component may also contain one or more isocyanate functional prepolymers, for example Desmodur PF, Mondur PF, or Isonate Μ 342. These prepolymers are generally reaction products of diphenylmethane diisocyanate or diphenylmethane diisocyanate oligomers and dipropylene glycol and / or tripropylene glycol; reaction products of such prepolymers with a sub-molar amount of polyol; reaction products of diphenylmethane diisocyanate with a sub-molar amount of long chain bifunctional polyols; urethane-imine modified diphenylmethane diisocyanate derivatives such as, for example, Suprasec 2020 or Desmodur CD, wherein the modification relates in particular to the presence of side groups or side chains. Suitable compounds for forming such side groups are allophanates and carbodiimides; reaction products of such modified modified isocyanates with a sub-molar amount of polyol. Other isocyanate functional polymers suitable for use in this invention include those derived from diisocyanates such as toluene diisocyanate, hexane diisocyanate, hydrogenated diphenylmethane diisocyanate, isophorone diisocyanate.

The first component may further contain the usual additives, for example one or more plasticizers, silica, zeolites, accelerators, fillers and / or other usual additives such as pigments, thixotropic agents and the like.

The first and second component will usually be a liquid, the viscosity of which will increase with mixing. After mixing the first and second components in the appropriate ratio, it is important that the mixture is used as quickly as possible.

If desired, the panel can be pre-coated with a so-called primer coating. This will usually be done if the surface of the panel on which the tiles are applied has an undesirable color that remains visible through any joints. By applying the primer, the color of the panel surface can be performed as desired. Various compositions can be used as a primer. However, according to this invention, a composition is preferably used based on a one-component polyurethane composition. Such a one-component polyurethane composition usually contains a prepolymerized diisocyanate, for example prepolymerized diphenylmethane diisocyanate and a pigment, for example activated carbon or any other pigment deemed suitable by the person skilled in the art.

Various methods can be used to manufacture the prefabricated panel.

In a method according to the invention for producing a prefabricated panel for constructing or coating a wall, a trace of an adhesive is applied to one side of a supporting panel, according to a predetermined adhesive pattern, after which on one side, at the positions where the adhesive is located, a plurality of bricks are positioned according to a predetermined pattern, the adhesive being a two component polyurethane adhesive as described above. The trace of adhesive may take various forms, and may, for example, be in the form of a rope, a hose or a series of consecutive points or stripes or any other form deemed suitable by the skilled person. This can be achieved, for example, by extrusion of the adhesive through an extruder opening above the panel. The adhesive of this invention offers the advantage that it cures quickly, thereby enabling automated production of stone-clad panels. On the other hand, the curing time of the adhesive is sufficiently slow to allow positioning of the bricks on the panel.

In a preferred method of this invention, prior to applying the adhesive, the panel surface is treated with a primer coating as described above, to provide the panel surface in a suitable color.

The panel can be made from various materials, for example from an insulating plastic, for example expanded polystyrene, polyurethane, XPS, glass wool, metal for example galvanized steel, but other metals can also be used, panels made from one or more mineral raw materials, for example basalt (Rockpanel < !>), or any other material deemed suitable by the skilled person. One side of the panel, in particular the side of the panel facing towards a rear wall or structure, may be provided with fixing means for facilitating the mounting of the panel on the rear wall or structure or frame. As fastening means, use can be made of those means which are generally known and which are considered suitable by the person skilled in the art. Fastening means that can cooperate with any fastening means present on the rear wall or structure may be preferred.

The invention is further elucidated with reference to the attached drawing.

Figure 1 shows a cross-section of a prefabricated panel 1 according to the present invention, wherein the prefabricated panel 1 comprises a load-bearing panel 10, one side 11 of the load-bearing panel 10 being coated with a plurality of stones 2, which are adhered to the adhesive panel are attached.

The panel 1 used in this invention can have various shapes, for example, it can have a regular geometric shape, for example, be circular, rectangular or square or triangular or any other shape suitable for the circumstances in which the panel will be used. The panel 1 can also have an irregular geometric shape. According to this invention, a rear wall can be covered with a plurality of panels with the same dimensions and shape, but a wall can also be covered with a plurality of panels, one or more of which have a different shape and different dimensions. The adjacent sides of adjacent panels can be provided with connecting means that facilitate the positioning of panels relative to each other. Adjacent sides can for instance be provided with cooperating interlocking connecting means, for example a tongue and groove connection or any other connection known to the person skilled in the art.

The stones 2 that are applied to the panel 10 can be constructed from various materials, for example natural stone, for example bluestone, granite, marble, slate, glass, baked stones such as bricks, halved bricks or any other stone material that is considered suitable by the skilled person. In addition to stones, materials such as metal, for example metal strips, can also be used to coat the plates. A panel 10 can be completely covered with stones 2 of the same material, or with a plurality of stones or plates or strips of different materials. A panel 10 can be entirely covered with bricks or strips 2 of the same dimensions, or with bricks and / or strips of different dimensions. With dimensions is meant dimensions in width, length and thickness direction of the brick or strip. The stones or strips 2 can be arranged according to a regular geometric pattern, or a combination of several different geometric patterns can be used. It is possible to use a single sawing line or to combine several sawing lines, i.e. bricks of different thickness, if the intention is to create an intense composition with a character-varying relief. The known brickwork dressings such as half-brick, standing or game dressings can be used, but also combinations of two or more of these dressings with, for example, horizontal, vertical and even diagonal brick layers. The use of the glue described above makes it possible to apply bricks or strips of a different material to a panel according to patterns and in combinations that can no longer be realized with classical building techniques * and with classical building materials, due to the complexity of the pattern and associated costs.

To manufacture the prefabricated panel of this invention, a trace of an adhesive 5 is applied to the side 11 of the panel to be coated, according to a predetermined pattern. This is preferably done by means of an extruder head, and the displacement of the extruder head is controlled by a control unit, on the basis of a pattern for positioning the bricks stored in the control unit. Simultaneously with or after application of the adhesive 5, the stones or strips 2 are positioned on the panel 10 according to the pattern stored in the control unit and the adhesive is allowed to cure. Since the adhesive 5 has a curing time that is relatively short, and varies for example from 1 minute to about 20 minutes, the panels can be removed from the machine after a short time and a short production time can be used.

Claims (15)

CONCLUSIONS. A prefabricated panel (1) for constructing or covering a wall, the prefabricated panel (1) comprising a load-bearing panel (10), wherein one side (11) of the load-bearing panel (10) is coated with a A plurality of bricks (2), which are attached to the panel with an adhesive agent (5), characterized in that the adhesive agent is a two-component polyurethane adhesive consisting of a first and a second component that react with each other upon contacting wherein the first component contains a diisocyanate and the second component contains: - 40.0-70.0 wt. % of one or more polyether polyols, one or more polyester polyols, one or more polyether polyester polyols or a mixture of two or more of the aforementioned polyols and a maximum of 0.15 wt. %, preferably a maximum of 0.10 wt. % of a catalyst for catalysing the reactions between the first and the second component, the second component being 0.5-2.5 wt. % of one or more amines, the amine containing at least one active H group capable of reacting with an isocyanate. A prefabricated panel (1) according to claim 1 or 2, wherein the second component further comprises 5.0 -15.0 wt. % of one or more zeolites. A prefabricated panel (1) according to claim 2, wherein the amine is a tertiary amine containing at least one tertiary amine group, preferably at least two tertiary amine groups. A prefabricated panel according to any one of the preceding claims, wherein the amine contains an alkanol group. A prefabricated panel according to any one of the preceding claims, wherein the amine is selected from the group of N, N, N'-trimethyl-N-hydroxyethyl-bisaminoethyl ether, Ν, Ν-bis (3-dimethylaminopropyl) -N- isopropanol amine, N- (3-dimethylaminopropyl) -N, N-di-isopropanolamine, N, N-dimethylethanolamine and 2- (2-dimethylaminoethoxy) ethanol or a mixture of two or more of the aforementioned amines. A prefabricated panel (1) according to any one of the preceding claims, wherein the diisocyanate is an aliphatic diisocyanate. A prefabricated panel according to claim 6, wherein the diisocyanate has an isocyanate functionality of at least 1, preferably at least 2, more preferably from about 2 to about 3.5, most preferably from about 2.5-3. A prefabricated panel according to claim 6 or 7, wherein the diisocyanate is selected from the group of hexamethylene diisocyanate (HDI), hydrogenated methyl diisocyanate, dodecane diisocyanate or a mixture of two or more thereof. A prefabricated panel according to any one of the preceding claims, wherein as polyether polyol use is made of a polyol selected from the group of poly (1,2-propylene oxide) glycol and poly (1,3-propylene oxide) glycol, poly (tetraethylene oxide) glycol, poly (pentamethylene oxide) glycol, poly (hexamethylene oxide) glycol, poly (heptamethylene oxide) glycol, poly (octamethylene oxide) glycol, poly (nonamethylene oxide) glycol, and poly (1,2-butylene oxide) glycol , as well as block copolymers of ethylene oxide and / or 1,2-propylene oxide or a mixture of two or more of the aforementioned polyethers, A prefabricated panel according to any one of the preceding claims, wherein the polyester polyol used is an ester based on an aliphatic dicarboxylic acid, preferably adipic acid or phthalic acid and a polyol, preferably ethylene glycol, butanediol, neopentyl glycol, hexanediol, propylene glycol, dipropylene glycol, diethylene glycol and cyclohexanedimethanol, or a mixture of two or more of these. A prefabricated panel according to any one of the preceding claims, wherein the polyol used is a diol or a triol or a mixture thereof. A prefabricated panel according to any one of the preceding claims, which is provided on a side facing the wall to be coated with fixing means for fixing the panel to the wall. An adhesive according to any of claims 1 to 12 for use in a prefabricated panel. A method of producing a prefabricated panel (1) for constructing or coating a wall, wherein a trace of an adhesive is applied to one side (11) of a load-bearing panel (10) according to a predetermined pattern, whereupon a plurality of bricks (2) are positioned on one side at the positions where the tackifier is located according to a predetermined pattern, wherein the tackifier is a two component polyprethane glue, according to any one of claims 1 to 12. A device for producing at least one prefabricated panel (1) for constructing or covering a wall, the device comprising a control unit for controlling a lijon one side (11) of a load-bearing panel (10) a trace of an adhesive is applied, according to a predetermined pattern, after which a plurality of stones (2) are positioned on the adhesive, according to a predetermined pattern, wherein the adhesive is a two-component polyurethane adhesive, as claimed in any one of claims 1 to with 12.