DE4432110A1 - Foam plastics tile underlay plate obtd. at low cost - Google Patents

Abstract

The foam plastics plate, pref. as an underlay for tiles and other building cladding materials, has an applied adhesive layer with a bonding agent content, or the bonding agent is applied to a heated or molten foam surface. The tile or other cladding is applied directly to the plastics layer or the foam surface treated with the bonding agent.

Description

The invention relates to a plastic building board, preferably as a base for tiles or other building structures Coatings.

Recently, building boards on buildings have become increasingly important acquired.

For the application of tiles, a very level and as possible precise, vertical or horizontal subsurface required. Earlier a mortar bed was applied. Especially with vertical ones The arrangement of the tiles will be considerably finished needed. With building boards you can easily without special manual skills a very level and vertical or represent a horizontal surface. The tiles can then be used be applied with a tile adhesive. The tile adhesive is in a very thin layer, e.g. B. applied with a notched trowel. The tiles then only need to be hung up or slightly be pressed. There is hardly any risk of unevenness given.

Originally, plasterboard and other known building boards applied. Win in more recent times Plastic foam building boards are of great importance. These Building boards have the great advantage over plasterboard high thermal insulation. In addition, the plastic foam plates depending on the training a more or less strong moisture insulation.

However, the plastic foam panels do not adhere to structures usual adhesives still stick to the masonry or concrete the tiles with the usual adhesives on buildings directly on the art fabric foam. That is why the plastic foam sheets are with a Apply mortar layer. The layer of mortar is relatively brittle. Without Reinforcement exists on mortar-coated panels in the rough building drove the risk of cracks in the mortar coating. That will be with  the known building boards with the help of a textile reinforcement different.

A major disadvantage of using plastic foam building boards Mortar coating compared to other building boards is the high gesture starting price. This price leaves many builders too technological inferior, but cheaper solutions. The invention the task is therefore based on the cost of building boards Reduce plastic foam.

According to the invention this is achieved in that on art a plastic layer is applied, the proportions of Has binders and that the tiles / coating immediately is applied to the plastic layer. Alternatively, it can Binder according to the invention in the heated or melted Foam surface can be brought and will flow sen / coatings laid directly on the foam surface. To the The usual tile adhesives mentioned above are used for laying have been. The tile adhesives are usually Cement-based adhesive, some with plastic parts. All these Adhesives are designed with a mineral base to connect. According to the invention, the necessary mineral substrate created by the binder. The The binder is either sand and / or ground minerals and / or ground plastic waste with a mineral content of at least 50% by weight and a grain size up to max. 3 mm.

The grain size of the binder depends on the process for Apply the plastic layer when the binder is part of the plastic insert, d. H. mixed with the plastic insert is. The particle size of the binder is then e.g. B. less than the opening width in the application nozzle when spraying the art fabric or smaller than the play of the extruder tools Extrude the plastic.

Preferred method for the subsequent application of the binder Sanding is on the foam surface. The Particles of the binder on the foam surface or the worn plastic layer sprinkled. It is favorable if the  Particles in the adhesive surface of the foam or the adhesive the surface of the plastic layer. To a rolling process is particularly suitable. The material, which none adequate connection with the plastic layer or the art foam is received, can then be brushed off and / or be sucked off. The same comes in a tapping / shaking Consideration.

The surface of the plastic foam becomes adhesive when it is sufficiently heated and / or melted.

The applied plastic layer is particularly adhesive when applied hot. The prerequisites for hot application are tongues for an adhesive effect with the foam surface and with binder medium particularly cheap. The plastic layer has one Detention function. The hot application can be done by extrusion.

As an alternative to plastic, a hot melt can also be used as an adhesive layer glue can be used.

When applying hot and / or heating / melting the foam surface There may be additional benefits if the binder Has additives on plastic particles. The plastic particles melt and give an additional strengthening effect in the applied binder layer. Advantageously no essential requirements for the plastic additives placed so that waste / residues there in accordingly shredded form can be used. The binder is said to however, maintain at least 50% by weight mineral content.

The adhesive layer can also be applied cold. It is suitable for this as plastic z. B. polyurethane. Polyurethane also unfolds in cold (room temperature) condition a very strong adhesive effect.

The plastic used for the adhesive layer can be foamed or can be applied without foam or extruded.

If the plastic foam forming the actual building board is a sufficient strength for the intended use, including flexural strength, has no further requirements for the coating.  

Then foaming plastic as an adhesive layer is sufficient chatting.

If the strength of the actual building board is insufficient forming plastic foam, the adhesive layer can be a special one Strength are given. This can be done by choosing an appropriate one Plastic and / or by reinforcing the adhesive layer or Surface of the plastic foam forming the actual plate can be achieved. A textile and / or bare fibers can be used as reinforcement to serve. Fabrics and nonwovens made from glass fibers are particularly suitable or plastic fibers. Fabrics have a special tensile strength, because they are ordered in the direction of the train. Become fleeces connected to each other with less order or disorderly, e.g. B. through glue, and have a lower strength, are for it but also much cheaper.

The strength of the adhesion applied to the plastic foam layer, especially plastic layer, is u. a. from the shift thickness depending. Depending on the layer thickness, the adhesive layer has so much Strength that they are the strength deficit of the plastic foam balances and no additional reinforcement in the form of a textile or fibers is required.

According to the invention, a layer thickness of up to max. 1.5 mm chosen. As a rule, the layer thickness is less than 1 mm. Soon the layer probably has a relatively high strength. This is with Helped by thickening. The thickenings can change the shape of jetties. The thickenings are preferably on the foam side arranged and it becomes unfoamed plastic for adhesion used. The thickening / webs are particularly cheap Shape through shaping recesses in the plastic foam. These Recesses can e.g. B. with the help of an embossing roller in the Press in the plastic foam that forms the actual plate. The happens with subsequent melting of the plate surface.

Alternatively, the recesses can be machined into the plate top surface are incorporated. This can be done simultaneously with the confectionery ionization of the plates or before or after assembly of the Plates are made. Packaging here means processing the  an extruder emerging plastic foam strand. The art Foam strand has a compared to the desired sheet size Excess and is preferably obtained by milling to the desired Plate thickness and plate width brought. This is preferably done with milling drums, between which the plastic strand is pushed becomes.

The recesses can be made simultaneously with the assembly work in that the milling drums are designed accordingly are, d. H. a bead of milling teeth adapted to the recesses have. The use of profiled milling drums requires that the Milling movement takes place in the direction of the desired recesses.

In the case of incorporation / milling of the Separate milling vehicles are used for recesses.

The recesses forming the thickenings according to the invention have a Width of 0.5 to 2 mm and a depth of 0.5 to 2 mm and one Distance up to 40 mm. They run in the longitudinal direction of the plate and / or across or only in the longitudinal direction of the panel or only across.

When coating the plastic foam panels, the recesses filled with the coating material.

It is favorable to use a polystyrene coating for art polystyrene foam sheets. The coating material can also contain proportions of copolymers or blends. As a co-polymer Polyphenylene oxide (PPO), acrylates, polymethyl methac are also suitable rylate (PMMA), especially derivatives of polystyrene. In the sense of the Waste from polystyrene derivatives is also an invention.

The blends in particular use polyolefins.

In the drawing, an embodiment of the invention is Darge poses.

Fig. 4 shows a process scheme. With 1 an extruder is referred to, the feed mixture, in the present case polystyrene with blowing agent, is supplied from a mixing station 2 . The feed mixture is plasticized and heated in extruder 1 . Gas is released by heating the blowing agent. After the plastifi ed plastic material emerges from the extruder 1, the plastic material foams. According to the nozzle of the extruder, a strand of plastic foam emerges, the thickness of which is greater than the plate thickness.

In a station 3 , the plastic foam strand is made up on the outer surfaces, that is, milled to panel thickness and width dimensions. At the same time, slots are milled in the longitudinal direction and transversely to the longitudinal direction. In the exemplary embodiment, the slots have a width of 1 mm and a depth of 1 mm. The distance between the slots is 10 mm. The surface creates a surface shown in FIG. 2. The surface of the plastic foam material designated 10 shows truncated pyramid-shaped elevations 11 , between which the recesses extend as slots in the longitudinal and transverse directions of the plate. The depth of the slots is 13 , the width 12 . The distance between the slots results from dimension 14 of elevation 11 .

After assembly in station 3 , a plastic mixture is then extruded onto the plate surface in station 5 , which is made of polystyrene with 20 wt. PMMA exists. The layer also contains sufficient amounts for a violet color. The layer is impact-resistant and tough. The layer thickness between the recesses in the exemplary embodiment is 1 mm. It is max. 1.5 mm. When coating, the recesses / slots are completely filled. The layer is not foamed. It combines well with the plate surface even at room temperature. In other exemplary embodiments, in order to improve the adhesion, the surface is heated immediately before the layer 16 is extruded, and possibly even melted on very slightly.

The still hot layer 16 is sanded at 6 a. For sanding, either mortar waste with ground plastic waste from a building board production can be used. The mortar waste is also ground if necessary. In the exemplary embodiment, the grain size is max. 1.5 mm. In another embodiment, sanding is carried out with natural sand of the same grain size. The sand is then rolled on. The particles that do not adhere sufficiently are brushed off and sucked away. Fig. 1 shows the resulting building board, consisting of the polystyrene foam layer 10 , the unfoamed polystyrene layer 16 and the sanding designated 21 . The polystyrene layer 16 has webs 30 and 31 which bring about a substantial reinforcement of the building board.

The building board shown is shown in Fig. 1 pivoted by 180 degrees compared to the representation of FIGS. 2 and 3.

Fig. 5 shows a possible application of the building board produced. According to FIG. 5, the building panel has been used as an angle element. It has according to Fig. 5 legs 33 and 34. The building board was mitered to produce the angle. The miter cut cuts through the plastic foam, but not the layer 16 with the webs 30 and 31 . The outside provided with the sand layer 21 angle element can be hen directly verse with tiles. Ie the tiles can be applied directly to the corner element after its positioning on a building corner.

In a further embodiment, the foam surface a textile is laid and enclosed by the coating and with connected to the foam surface. Instead of the textile (fabric or Fleece), bare fibers can also be used.

Claims (13)

1. Building board made of plastic foam, preferably as a base for tiles and other coatings occurring on buildings, characterized in that

• - An adhesive layer is applied to the plastic foam, which has proportions of binder
• - Or the binder is brought into the heated or melted foam surface
• - And the tiles / coating is applied directly to the plastic layer or directly to the foam surface provided with binder.

2. Building board according to claim 1, characterized in that the Adhesive layer is a plastic layer. 3. Building board according to claim 2, characterized by an un foamed plastic layer. 4. Building board according to one or more end claims 1-3, characterized characterized in that the binder sand and / or ground Minerals and / or ground plastic waste with one Mineral content of at least 50% by weight and a grain size up to Max. Is 3 mm. 5. Building board according to claim 4, characterized by a grain size, which is smaller than the nozzle opening when spraying plastic is. 6. Building board according to claim 3, characterized in that the Grain size smaller than the clearance between the extrusion works is witness.   Building board according to one or more of claims 1-5, characterized by rolling in and / or brushing and / or Shaking and / or tapping and / or sucking the sanded Surface. 8. building board according to one or more of claims 1-6, characterized by thickening and / or webs of Plastic layer. 9. Building board according to claim 7, characterized in that the Thickenings are on the foam side and are corresponding in the foam Recesses. 10. Building board according to claim 8, characterized in that the Recesses molded into the heated foam surface or be machined. 11. Building board according to claim 9 or 10, characterized in that the thickenings 0.5-2 mm depth, 0.5-2 mm width and Have distances of up to 40 mm. 12. Building board according to one or more of claims 8-11, characterized characterized in that the plastic layer between the thickenings a thickness of max. 1.5 mm. 13. Building board according to one or more of claims 1-7, characterized net by a textile or fibers as reinforcement between the Foam surface and the coating or in the coating.