DK2591181T3

DK2591181T3 - Gypsum-based plasterboard and method for laying it

Info

Publication number: DK2591181T3
Application number: DK11730282.8T
Authority: DK
Inventors: Stephan Duckwitz; Erwin Borns
Original assignee: Saint-Gobain Placo Sas
Priority date: 2010-07-09
Filing date: 2011-07-04
Publication date: 2017-09-11
Also published as: PL2591181T3; WO2012004220A2; EP2591181B1; WO2012004220A3; EP2591181A2

Description

The invention concerns a perforated plate on a gypsum base, together with a method for the laying of the same on a substructure for the manufacture of, in particular, a suspended ceiling or a wall, wherein the joints between the individual perforated plates are filled by means of a filling material and are subsequently ground smooth.

Such perforated plates on a gypsum base, in particular gypsum board perforated plates and gypsum fibre perforated plates, are primarily deployed in large rooms in suspended ceilings, but also in wall structures, amongst other reasons so as to improve the room acoustics. These perforated plates usually have a grid-shaped, regular hole pattern. The costs of such a structure depend significantly on a rapid and thus convenient assembly procedure.

The time required for assembling the perforated plates, together with the labour required, is determined predominantly by the effort required for the alignment of the perforated plates relative to one another. Any deviations in the spacing of the holes in the transitions between plates, or any deviations in the runs of holes as a result of non-parallel alignment, are very obtrusive by virtue of the hole patterns. To this end, aids are used in the assembly, which are adapted to the spacing of the holes of the perforated plates that are being used in the individual case; with these aids an appearance that meets visual requirements can be ensured with the formation of a joint between adjacent perforated plates; the latter is filled with a filling material and subsequently ground smooth. However, this form of assembly requires at least two people during the alignment of the plates, which has a detrimental effect on the costs.

To improve on this prior art, a number of solutions have been proposed, which are based in particular on the use of perforated plates that are particularly accurately dimensioned; a production method for such plates on an industrial scale is disclosed, for example, in EP 1 369 215 A1.

In what follows, EP 1 369 215 A1 describes a ceiling structure with perforated plates that have been produced in this way; these are laid directly butting against one another without joints, such that only a hairline joint remains. While an easier laying procedure is in principle provided by this means, it is however linked with two disadvantages. By virtue of the lack of a joint region, it is not possible to compensate for any differences in the thickness of adjacent plates: Furthermore, the edges are subject to an increased risk of damage; even in the case of minor damage this leads to visual impairment of the hairline joints, which can only be remedied with time-consuming repairs before the ceiling is finally coated. In addition, the hairline joints only have a low strength. WO 2005/059267 A1 from the same applicant attempts to circumvent the disadvantage of the lack of ability to compensate by laying the gypsum board plates with the smallest possible joint width, preferably butting against one another, and by applying a cover strip to the joints. After the application of a filling emulsion paint, the cover strips are levelled by grinding such that they can no longer be detected after the final coating. Due to the fact that the joints between adjacent plates are not filled with filling material, the disadvantage of low joint strength is still present in this method. WO 2006/067213 A1 discloses a perforated plate on a gypsum base, which is also particularly dimensionally stable, in which at least two side surfaces are designed with rebates. During the assembly of the plates, this is carried out in such a way that the plates butt against one another and a perforated plate with a side surface with a rebate abuts against a side surface without a rebate so that a gap remains, facing into the space. The gap that is thus created can be filled in the usual manner with a filling or grouting material. By virtue of the closure of the rear side of the joint the filling material can no longer exit from the joint, so that the grouting can be undertaken more easily and should be more durable. While relinguishing this advantage, provision can also be made for the rebate not to be formed over the entire length of an edge; instead it can also be distributed completely or partially over some regions. In such a case the remaining rebate can be reduced to 10 % of the edge length in question, which is sufficient for purposes of easing the alignment procedure. For standard perforated plates with the dimensions 1200 x 2000 mm, this means that with two rebate bars on the edge face a minimum length of 60 mm must be maintained for each, since, with shorter dimensions, it is apparent that an increased risk of damage, such as fracture of the said rebate bars, which are made of gypsum, exists during transport, storage and processing. While WO 2006/067213 A1 does disclose an improvement compared with the prior art, the production of the perforated plates with rebates is comparatively complicated and expensive, particularly in the case of perforated plates with partially distributed rebates. EP 2 199 478 describes a perorated plate in accordance with the preamble of claim 1.

Based on this prior art, the object of the invention is to provide a perforated plate based on gypsum, which overcomes the disadvantages of the prior art and at the same time is simple and cost-effective to produce. A further object of the invention is to provide a method for laying the inventive perforated plates.

The first object is achieved by a perforated plate based on gypsum with the features of claim 1. The second object is achieved by a method for laying the inventive perforated plates with the features of claim 10. Preferred embodiments are the subject matter of the respective subsidiary claims.

The inventive perforated plate based on gypsum with a front and a rear side and four side surfaces has spacer elements on at least two side surfaces, which are formed from a material other than the base material of the perforated plate, and whose total length does not exceed 5% of the length of the respective side surface.

Here the solution is based on the concept, starting with a particularly dimensionally stable perforated plate, of avoiding the step of complete or partial rebating, which is time-consuming and costly to produce. Instead, prefabricated spacer elements are arranged on a perforated plate, which with their width specify the width formed by the joint between two adjacent perforated plates, and are designed in such a way that a visually uniform appearance is created. With a suitable choice of materials, the dimensions of the spacer elements can be kept small, since damage such as fracture and the resulting loss of ease of alignment capability is not to be expected, as is the case with gypsum. In addition, virtually the entire side surface or edge of adjacent perforated plates is available as an adhesive base for the filling material, for the formation of a high strength joint.

The connection of the spacer elements to the perforated plate is implemented by way of the side surface adjacent to the spacer elements, and/or by a region of the rear side. The connection is most simply configured by way of the side surface itself, since the spacer element and the perforated plate edge have direct contact surfaces, and thus a direct connection between the contact surfaces is possible. For a connection by way of a region of the rear side, the spacer elements have a tab-form extension, which is seated on the rear side.

The spacer elements are preferably formed from metal, particularly preferably a rust-resistant metal, such as aluminium, or from a plastic material.

The spacer elements can be mechanically attached to the perforated plate, for example by the use of screws, rivets, or nails, or are attached by adhesive means, preferably by gluing. Spacer elements can also have spikes or comparable attachment elements, in particular of metal, which enable a direct attachment without any other elements. In a similar manner self-adhesive coatings also enable a direct attachment without any other attachment means.

The spacer elements are matched in their dimensions to the hole pattern, to the effect that the result is a visually uniform appearance. The arrangement of the spacer elements is matched to the thickness of the perforated plate such that the spacer elements are set back in relation to the front side. As a result, a continuous joint is formed in the laying procedure, which can be filled with a filling material, and any visually conspicuous interruption of the joint or joints to be filled by the spacer elements is excluded.

In one form of embodiment, the spacer elements can be formed in a point shape. Here the term "point shape" is to be understood to mean that a spacer element is formed from a mechanical attachment element, whose head height corresponds to the required distance between two adjacent plates for a visually uniform appearance.

In an alternative configuration, the spacer elements can be formed in a square shape. Here it is preferable for the height of the spacer elements to be approximately half the thickness of the perforated plate. In an arrangement that is flush with the rear side of a perforated plate, the result is a joint with a depth of approximately half the thickness of the plate in the region of the spacer element.

It is preferable for the spacer elements to be arranged on two adjacent side surfaces that meet up with one another at a corner of the plate. It is particularly preferable for at least one spacer element to be arranged less than 10 cm from a corner of a side surface. In this manner any tilting of the two perforated plates that are abutting one another can advantageously be avoided.

In a preferred embodiment, the spacer elements are formed in a cross shape with four square-form webs. In the arrangement of such a cross-shaped spacer element in a corner of the plate, two webs then extend in an extension of the two edges forming the corner of the perforated plate. This offers the particular advantage that, with the cross-shaped spacer elements, not only the parallel alignment of two abutting plates, but also an alignment perpendicular to this direction is already predetermined. This makes the effort of aligning the surfaces considerably easier. Functionally, such a cross-shaped spacer element corresponds to a spacer element in all four joints extending from this corner in the installed state, as a result of which the number of spacer elements is reduced by a factor of four. In the case of plates for which, in the installed state, adjoining plates do not interface on all plate edges (edge plates), the attachment of T-shaped spacer elements is always advantageous and sufficient, if on the plate corners only two plates must abut against each other and be aligned with each other. The cross-shaped spacer element can be made ready for such a use, in that at least one web is equipped with a defined line of fracture. In the event that the installation requires a T-shaped spacer element, one web of the cross-shaped spacer element can be broken off and the installation of the remaining T-shaped spacer element can be implemented in a simple manner.

The spacer elements can be attached to a perforated plate at the time of production, but it is also possible to fit the spacer elements onto the perforated plate only during the laying procedure on-site. It is also possible to integrate the spacer elements during the laying procedure in such a way that they are not fixed at all to the perforated plate; rather, for example, the flat rear-side tabs of the spacer elements are simply pushed between the substructure and the rear side of the perforated plate, thus fixing the spacer element onto the plate edge of the perforated plate that is being laid. Likewise, spacer elements that have dropped out or have been broken off during transport, storage and/or the laying procedure can easily be replaced as necessary.

The laying of the perforated plates to form a visually uniform, "uninterrupted" planar structure is not significantly different from the method of known art per se, provided that the spacers are fitted at the time of production. Otherwise, these can be fitted to the perforated plate on-site before the perforated plate is attached to the substructure, or also thereafter. At least one other perforated plate is abutted bluntly against the spacer elements and aligned with the hole pattern of the first perforated plate. This step is then repeated. A joint is left between the adjacent perforated plates, which is filled with a filling material in a manner of known art per se, ground and then coated, in order to obtain a homogeneous and uniform appearance.

In what follows preferred examples of embodiment are described with reference to the drawings, wherein the same reference symbols designate similar objects. Here:

Fig. 1 shows a perspective view of an inventive perforated plate based on gypsum with spacer elements, with a detail of a first spacer element,

Fig. 2 shows a perspective view of a further inventive perforated plate with a detail of a second spacer element,

Fig. 3 shows a perspective view of a third form of embodiment of an inventive perforated plate with a detail of a third spacer element,

Fig. 4 shows a perspective view of a fourth form of embodiment of an inventive perforated plate with a detail of a fourth spacer element.

Fig. 1 shows a perforated plate 1 with a front side 2 as a visible side, a rear side 3 (not visible), two short side surfaces 4' and two long side surfaces 4"; also indicated is a hole pattern 5. The dimensions of the body of the plate are, as usual, 1200 x 2000 x 12.5 mm. On two adjacent side surfaces 4' and 4", which make contact at a corner 6, two spacer elements 7 are fitted in each case at a distance of less than 100 mm from the corner 6, and less than 100 mm from the opposing corner 6' or 6" bounding the side surface 4' or 4" as appropriate. The square-form spacer elements 7 advantageously have uniform dimensions so as to reduce the number of variants, and are arranged flush with the rear side 3. The length of the spacer elements 7 is 30 mm, and the height is 6 mm, so that in the installed state a joint is formed in the region of the spacer elements with a depth of approximately half the thickness of the perforated plate. The width of the spacer elements 7 is matched to the hole pattern 5 such that in the installed state a visually uniform appearance is ensured. The total length of the spacer elements 7 serving as a stop and completely sufficient for precise alignment is 60 mm in the direction of a side surface 4' or 4" respectively.

In the example of embodiment the spacer elements 7 are attached to the side surfaces 4' and 4", respectively, with an adhesive, not shown. In the example of embodiment, the spacer elements 7 are injection-moulded parts of plastic, in particular of PE or PP.

In the example of embodiment the spacer elements 7 have already been fitted to the perforated plate at the time of production. However, it is also possible to attach the spacers 7 only before starting the laying procedure on-site, or even during the laying of the perforated plates.

Fig. 2 shows a further form of embodiment of the inventive perforated plate, which differs from the embodiment in Fig. 1 only in the type of spacer elements 8. The point-form spacer elements 8 have a cylindrical head 8' with a diameter of 6 mm, that is to say, approximately half the thickness of the perforated plate. The height of the head 8' is, as for the width of the square-form spacer elements 7, matched to the hole pattern 5. On the head is located an attachment element 8" in the form of a spike, which serves to provide a mechanical attachment of the spacer element 8 on or in the side surfaces 4' and 4" respectively. The spike-form attachment element 8" can alternatively also be provided with a thread, which enables the element to be screwed into the side surfaces 4' or 4" respectively. The cylindrical head of such an attachment element then preferably has conventional devices for receiving an appropriate screwing tool for purposes of screwing the spacer element onto the edge of the perforated plate.

In the example of embodiment the spacer elements 8 are manufactured in metal. In a corner region more than one spacer element 8 can also be arranged as required. Here the total length of all spacer elements arranged in this manner on a side surface does not exceed 5 % of the length of the side surface .

In this example of embodiment the spacer elements 8 have also already been fitted at the time of production, but can also, however, be first fitted on-site.

Fig. 3 shows a further form of embodiment of the inventive perforated plate 1 with a cross-shaped spacer element 9 that overlaps the corner 6 and functionally replaces the spacer elements 7 or 8 arranged in the region of a corner 6 on the two side surfaces 4' and 4" in the previously described examples of embodiment, and thus allows a reduction in the number of spacer elements. The alignment with the normal to a side surface predefined by the four square-form webs 9' considerably speeds up the laying procedure.

For the dimensions of the spacer element 9, those of the spacer elements 7 in the first example of embodiment are appropriate. The webs 9' have a length of 30 mm, and a height of 6 mm, together with a width that is matched to the hole pattern. This spacer element is also manufactured as an injection-moulded part from a plastic material, preferably from PE or PP, and is attached with an adhesive, not shown.

Because the webs project beyond the body of the plate, with an increased risk of damage during transport and storage, an onsite attachment of the spacer elements 9 is preferred. Needless to say, however, the spacer elements 9 can also be fitted at the time of production.

Fig. 4 shows a spacer element 10 with a square-form head 11 and a tab-form extension, which in the installed state overlaps the rear side 3 and a side surface 4 of the perforated plate. The connection of the spacer element 10 takes place by way of the tab-form extension 12 with the rear side 3 of the perforated plate, wherein the mechanical or adhesive means of attachment as described can be deployed; these are not shown. An adhesive form of attachment is preferred. In Fig. 4 the one-piece spacer element 10 consists of the head 11 and the tab-form extension 12, which are joined permanently together in a suitable manner, for example, by means of adhesive, welding, or similar. Alternatively the spacer element 10 can also be present as a single part, for example in the form of a plastic injection-moulded part.

It goes without saying that the form of the head 10 is not limited to a square shape, but can comprise other conceivable forms, such as a point shape or an ellipse shape. With sufficient material thickness it can also take the form of an angled element.

Claims

1. Gypsum board (1) based on plaster, in particular gypsum board or gypsum fiber board, with a front (2) and a back (3) and four side surfaces (4 ', 4 ") and with the spacers (7, 8 , 9, 10) on at least two side surfaces, characterized in that the spacer elements (7, 8, 9, 10) are formed of a material other than the material of the hole plate (1), and the total length of all spacer elements (7, 8). , 9, 10) placed on a side surface does not exceed 5% of the lower back lumbar.

Hollow plate (1) according to claim 1, characterized in that the spacer elements (7, 8, 9, 10) are formed of metal, in particular non-rusting metal, or of plastic material.

Hollow plate (1) according to claim 1 or 2, characterized in that the spacer elements (7, 8, 9, 10) are fixed mechanically or adhesively, preferably adhesively.

Hollow plate (1) according to one of claims 1 to 3, characterized in that the spacer elements (7, 8, 9, 10) are retracted relative to the front (2) of the hollow plate.

Hollow plate (1) according to one of claims 1 to 4, characterized in that the spacer elements (7, 8, 9, 10) are formed squared.

Hollow plate (1) according to claims 1 to 4, characterized in that the spacer elements (7, 8, 9, 10) are cross-shaped.

Hollow plate (1) according to one of Claims 1 to 4, characterized in that the spacer elements (7, 8, 9, 10) are formed in point form.

Hollow plate (1) according to one of claims 1 to 7, characterized in that a spacer (7, 8, 9, 10) is not located further than 100 mm from a corner (6, 6 ', 6 ").

Hollow plate (1) according to one of claims 1 to 8, characterized in that the spacer elements (7, 8, 9, 10) are located on the factory side.

A method of laying gypsum board (1) based on plaster according to at least one of claims 1 to 9, wherein a hole plate (1) is bluntly supported to a hole plate (1) with spacer elements (7, 8, 9, 10 ), and a joint between the two sheets is subsequently filled with a filling material.

A method of laying hollow sheets (1) on the basis of gypsum according to claim 10, wherein spacing elements (7, 8, 9, 10) are placed on at least two of its side faces (4 ') before the laying of a hollow sheet (1). , 4 ").

A method of laying hollow sheets (1) on the basis of gypsum according to claim 10, in which, when laying a hollow plate (1), spacers (7, 8, 9, 10) are placed on at least two of its side faces (4 '). , 4 ").