CH683706A5 - Tile panels backed by polyurethane foam and expanded polystyrene - Google Patents

Abstract

Insulation panels for covering walls or floors of buildings are made by lining the base of a mould with an array of prefabricated (clay) tiles (1), casting a layer (2) of expanded polyurethane resin over the backs of the tiles and covering the upper surface of the resin with a more rigid layer (3) of expanded polystyrene or of dense mineral fibres. Pref. coloured particles are sprinkled into the spaces between the tiles, to mask the resin and resemble conventional mortar (5). Pref. large, flat-headed pins (4) are trapped by the resin layer(s) against the reverse faces of the tiles and project sufficiently (approx. 50 mm) to support the panels by anchorage in holes drilled into the supporting wall and primed with a bonding agent. The panel may be shaped for mutual tongue (7) and groove (6) engagement.

Description

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Description

The present invention relates to prefabricated panels for thermal and acoustic insulation of walls and walls, as well as their manufacturing and installation process.

The invention more specifically relates to a prefabricated panel for the building and with a view to coating a support wall, this panel being of the sandwich type and comprising an exposed skin formed of juxtaposed plates and secured to an inner layer of expanded polyurethane, characterized in that the panel further comprises a face in contact with the wall and consisting of an insulating plate of expanded polystyrene or mineral fibers ensuring the insulation and rigidity of the entire panel and in that the inner layer of polyurethane expanded between the two external components is a polyurethane foam ensuring both the joining of the plates together and the joining of the whole.

And advantageously according to the invention, the plates constituting the apparent skin consist of plates in natural terracotta or with vitrified surface or in natural or reconstituted stone.

These plates are arranged in horizontal rows, the odd rows occupying the entire length of the panel, while the even rows have one less plate compared to the odd rows, the voids thus formed being capable of receiving fixing dowels.

The invention also relates to a method of manufacturing a prefabricated panel for the building, characterized in that the plates forming the visible skin and quartz powder which will materialize the horizontal joints are placed in the bottom of a mold. and vertical, the surface in contact with the wall is formed on the lower wall of the mold cover (thanks to a few points fixed to this cover) and is formed of polystyrene or dense mineral fibers, and the components are injected between the two a polyurethane foam, preferably a polyol and an iso-cyanate injected all at once, whereby contact with the crushed quartz locally annihilates the expansion effect and ensures local densification of the polyurethane.

This foam makes the whole monolithic, because it is very adhesive and it solidifies the ground quartz powder which materializes the horizontal and vertical joints of the visible plates or plates as in traditionally masonry masonry. The molds must be resistant because, during polymerization, the pressure inside the mold can reach 3 bars.

In the mold are provided recesses which allow the molding of male and female peripheral sockets in the central part of the polyurethane sandwich.

Polyurethane foam ensures the adhesion of visible plates and plates.

This polyurethane foam can also form a frame of a few millimeters around the panel of expanded polystyrene or mineral fibers so as to strengthen the periphery and give it a precise dimension which will be that of the mold.

Each panel is fixed to the walls by 4 to 6 flat-headed dowels with a diameter of approximately 30 mm and a total length of 150 mm, of which approximately 50 mm will penetrate the support wall and ensure good resistance to tearing of the panels.

Each panel can, in addition, be glued to the wall.

During prefabrication, the plates are placed in the bottom of the metal mold which has positioning bars with alternating seals; every other row, the plates reveal the exposed cellular insulator along the length of a half-plate.

A recess obtained by a boss projecting into the mold makes it possible to accommodate the large head of each ankle there. After installation: the connecting plates between panels are glued with glues and polyurethane sealant.

The two insulating materials each have their role: the polystyrene or the mineral fiber panel gives rigidity and the polyurethane ensures the bonding of the constituents: plates, quartz sand, polystyrene and mineral fibers.

The insulation from the outside allows the mass of existing walls to play their role of thermal flywheel: the interior useful surface of the housing is not reduced. The annual saving on heating can reach 40%.

Dimensions (given by way of nonlimiting example): height: 490 mm length, 1100 mm thickness: 100 mm weight: 30 kg per m2 approximately. The assembly is carried out by foaming the polyurethane on the plates placed at the bottom of the mold.

The accompanying drawings illustrate the invention:

fig. 1 shows in elevation a first embodiment of the panel according to the invention;

fig. 2 is a side view;

fig. 3 is a top view;

fig. 4 is a top view of a variant; and fig. 5 is a section along the line A-B, of a part of the panel shown in FIG. 1, of an adjacent part of a second panel with which the first is assembled, and of a support, and shows pegs fixing the panels to the wall.

The panels shown in fig. 1 to 4 each have an exposed skin 1 formed from several horizontal rows of plates secured to an inner layer 2 covering a plate 3.

The odd rows of plates starting from the top occupy the entire length of the panel, for example five plates of 210 mm in length plus five joints of 10 mm; i.e. a total length of 1100 mm.

The even rows include one less plate, that is to say four in the example of FIG. 1.

The voids thus formed 8 will, after fixing by pins 4 of a row of panels gar5

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nis of plates, placed between two panels; these plates being glued in place by a polyurethane-based sealant and compatible with polyurethane foam.

The arrangement of the plates then appears regular and the head of the fixing studs 4 then becomes invisible.

The panel shown in figs. 1 to 3 comprises a pair of female sockets 6 and a pair of male sockets 7, the horizontal male socket facing upwards, and the vertical male socket being placed on the left. The vertical sockets can be reversed from those shown in the drawings; they just need to be complementary and nestable.

Fig. 4 shows a particular case when the panel according to the invention is intended, for example, at the corners of buildings or to form door and window frames.

Claims (12)

Claims 1. Prefabricated panel for the building and with a view to coating a support wall, this panel being of the sandwich type and comprising an exposed skin (1) formed of juxtaposed plates and secured to an inner layer (2) of expanded polyurethane, characterized in that that the panel further comprises a face (3) in contact with the wall and consisting of an insulating plate of expanded polystyrene or mineral fibers ensuring the insulation and the rigidity of the entire panel and in that the inner layer of expanded polyurethane between the two external components is a polyurethane foam ensuring both the joining of the plates together and the joining of the assembly. 2. Panel according to claim 1, characterized in that the plates constituting the apparent skin consist of plates in natural terracotta or with vitrified surface or in natural or reconstituted stone. 3. Panel according to one of claims 1 and 2, characterized in that the plates are arranged in horizontal rows, the odd rows occupying the entire length of the panel, while the even rows have one less plate compared to the odd rows , the voids thus formed (8) being able to receive fixing pins. 4. Panel according to one of claims 1 to 3, characterized in that the joints between the plates consist of crushed quartz impregnated with dense polyurethane, unexpanded, which ensure their cohesion and their tightness. 5. Panel according to one of claims 1 to 4, characterized in that the face in contact with the wall is formed of expanded polystyrene or dense mineral fibers (3) in the form of a rectangular parallelepiped. 6. Panel according to one of claims 1 to 5, characterized in that the plastics (1) used in the composition of the panel are of an edible quality to ensure good resistance to the propagation of fire. 7. Panel according to one of claims 1 to 6, characterized in that the central polyurethane layer has along the edges of the sockets respectively male (6) and female (7) facilitating their juxtaposition as well as their subsequent disassembly for the purpose of their reuse. 8. Panel according to claim 7, that one of the lateral sockets, male or female is replaced by a corner plate (9). 9. A method of manufacturing a panel according to one of claims 1 to 8, characterized in that one places in the bottom of a mold the plates forming the visible skin and the quartz powder which will materialize the horizontal joints. and vertical, the face in contact with the wall formed of polystyrene or dense mineral fibers is subjected to the lower wall of the mold cover, and the components of a polyurethane foam are injected between the two. 10. The method of claim 9, characterized in that the polyurethane components, namely a polyol and an iso-cyanate, are injected at one time, whereby contact with the crushed quartz locally annihilates the effect of expansion and local densification of the polyurethane. 11. Method according to one of claims 9 and 10, characterized in that gray dye is added to the constituents of the polyurethane in order to obtain in particular for the visible joints a gray color related to that of cement. 12. Use of a panel according to one of claims 1 to 8 for coating a support, characterized in that the panel is fixed to the support wall by means of fixing pins arranged in the voids (8), after which the voids (8) are lined with plates placed astride two panels, these plates being glued in place by a polyurethane-based sealant and compatible with polyurethane foam, the head of the fixing dowels then becoming invisible. 5 10 15 20 25 30 35 40 45 50 55 60 65 3