EP2978908A1 - Perforated boards based on gypsum and methods used for laying - Google Patents

Perforated boards based on gypsum and methods used for laying

Info

Publication number
EP2978908A1
EP2978908A1 EP14714238.4A EP14714238A EP2978908A1 EP 2978908 A1 EP2978908 A1 EP 2978908A1 EP 14714238 A EP14714238 A EP 14714238A EP 2978908 A1 EP2978908 A1 EP 2978908A1
Authority
EP
European Patent Office
Prior art keywords
spacer elements
perforated
board
boards
perforated board
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP14714238.4A
Other languages
German (de)
French (fr)
Other versions
EP2978908B1 (en
Inventor
Frank CHRISTMANN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Placo SAS
Original Assignee
Saint Gobain Rigips GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Gobain Rigips GmbH filed Critical Saint Gobain Rigips GmbH
Priority to PL14714238T priority Critical patent/PL2978908T3/en
Publication of EP2978908A1 publication Critical patent/EP2978908A1/en
Application granted granted Critical
Publication of EP2978908B1 publication Critical patent/EP2978908B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0867—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having acoustic absorption means on the visible surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/34—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles
    • E04B9/36—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles consisting of parallel slats
    • E04B9/363—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles consisting of parallel slats the principal plane of the slats being horizontal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0892—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with means for aligning the outer surfaces of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B2001/6191—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means on the corners of the slabs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
    • E04B2001/848—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element
    • E04B2001/8495—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element the openings going through from one face to the other face of the element
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0464—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having irregularities on the faces, e.g. holes, grooves
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
    • E04F2201/0511—Strips or bars, e.g. nailing strips

Definitions

  • the invention relates to a perforated board based on gypsum and a method for laying on a substructure, in particular for constructing a suspended ceiling or a wall, whereby the joints between the individual perforated boards are filled by means of a filler and then smoothly sanded. Furthermore, the invention relates to a method for manufacturing such perforated boards.
  • Such perforated boards based on gypsum, particularly plasterboards and gypsum fibre perforated boards are primarily used as suspended ceilings in large rooms, but also for wall structures, amongst other things for improving room acoustics. These perforated boards usually have a gridlike, regular hole pattern. The costs for such constructions essentially depend on a quick and thereby cheap fitting.
  • EP 1369215 A1 describes in the following a ceiling construction with perforated boards, which are manufactured in such a manner, that the boards are laid closely adjacent to one another, so that only a slim joint remains visible. In principle, the laying of these boards is much easier; however, there are two main disadvantages. Due to the missing joint area, an adaptation to the varying thicknesses of adjacent boards is not possible. Furthermore, the edges are exposed to an increased risk of damage which, even in cases of minor damage, leads to visible impairments of the fine joints, which subsequently can only be remedied with costly repairs before the final painting of the ceiling. In addition, the fine joints only dispose of a limited joint resistance.
  • WO 2005/059267 A1 tries to avoid the drawback with regard to the lack of the possibility of adaptation of the same applicant, in that the plasterboards are laid with a relatively small joint width, preferably adjoining, and that a cover strip is applied on the joints. After the application of a filling emulsion paint, the cover strips are levelled out by sanding, so that they are no longer visible after the final painting. Due to the lack of filling the joint between adjoining boards with joint filling material, the disadvantage of the limited joint resistance persists.
  • WO 2006/067213 A1 likewise reveals a particularly dimensionally stable perforated board based on gypsum, of which at least two face sides are rabbet edged. When fitting the boards this is done in such a manner that the boards are laid closely adjacent to each other, and a perforated board having a side with rabbet edge meets a side without rabbet edge so that a room-facing joint remains.
  • the resulting joint can be filled in a conventional manner with a filler or filler material. Due to the rear end finishing of the joint, the filler material cannot leak out of the joint, so that the joining is much easier and is supposedly more durable.
  • the rabbet edge is not formed over the entire length of an edge, but can also be used in whole or in part. In such a case, the remaining rabbet edge can be reduced by 10% of the respective edge length, which is sufficient for facilitating the alignment.
  • WO 2006/067213 A1 is an improvement with regard to state-of-the-art technology, the production of perforated boards with rabbet edge is relatively complicated and expensive, especially the perforated boards with partially offset rabbet edge.
  • the invention sets the task of providing a perforated board based on gypsum which overcomes the disadvantages of state-of-the-art technology, and has a practice-oriented protection against damage during handling and transport, and at the same time is simple and inexpensive to manufacture. Further, the task of the invention is also to provide a method for laying the perforated boards and a method for manufacturing them.
  • the first task is achieved by a perforated board based on gypsum with the features of claim 1.
  • the second task is achieved by a method with regard to the laying of the inventor's patent perforated boards with features of claim 15.
  • the third task is achieved by a method with features of claim 16.
  • Independent protection is claimed for a stack of boards with the features of claim 16, a semi-finished product with the features of claim 22, a kit with the features of claim 23 and a method for the construction of ceilings and walls, using a kit according to claim 23 with the features of claim 24.
  • Preferred versions are subject matter of the respective sub claims.
  • the inventor's patent perforated board based on gypsum having a front and a rear side and four side faces, which form four corner edges, spacer elements in the form of an angle with two lateral (arm) sides and a connecting joint area, which connects one of the two lateral sides, which overlaps a corner edge and whose lateral sides rest on the corner edge of the adjacent face sides.
  • the solution sets out from the idea of using a particularly dimensionally stable perforated board in order to avoid the complex manufacture and costly measure of whole or partial rabbeting.
  • prefabricated spacer elements are arranged on a perforated board, whereby the laying of the spacer elements of a second perforated board can be butt-joined to a first perforated board, so that the width of the spacer elements forms a gap with a gap width, which is designed in such a manner that an optically uniform appearance is created.
  • the spacer element provides, apart from the size-adjusted joint width, a corner and corner edge protection against mechanical damage.
  • connection area between the two lateral sides is designed in such a manner that the arrangement of the connecting area allows at least one further spacer element in the area, which is formed by the overlapping area of the two mutually orthogonal joints in two adjacent side faces of the perforated board, in whose corner the spacer elements are arranged.
  • the overlapping area hereinafter referred to as the intersection area is rectangular, in particular square, since usually both joints have the same width.
  • the spacer elements can be kept small in size, since damages such as snapping off and the resulting loss of adjustability as in the case of plaster are not to be expected.
  • the entire side face or edge of each adjacent perforated board is practically available as an adhesive base for the filling material.
  • the lateral sides of the spacer elements have a width corresponding to the joint width.
  • the lateral sides touch each other along one edge and are connected by a connecting area.
  • the connecting area has an area in the angular level within the cross-section of no more than half the area of the intersection area.
  • At least two spacer elements are arranged in diagonally opposite corners, per perforated board.
  • four spacer elements in all four corners can be arranged, whereby the spacer elements of the second diagonally opposite corners are vertically offset at least in the height of the lateral sides or of the spacer elements of the second diagonally opposite corners, so that, when fitting the four spacer elements, these are arranged in an intersection area in the form of two vertically offset levels with two elements.
  • the connecting area in the form of an isosceles triangle with a lateral (arm) side length of the triangle corresponding to the gap width, so that in the intersection area, two diagonally offset spacer elements are form- fitted (inter-locked), with the ability to be arranged with its connecting area.
  • connection areas with another surface shape and / or a smaller surface, where only a partial or no form-fitting of the spacer elements are present in the intersection area.
  • the lateral sides of the spacer element have a width corresponding to the gap width and are offset vertically by at least the height of the lateral sides.
  • the connecting area has an area in the angular level within the cross-section of no more than a quarter of the area of the intersection area.
  • the connection area between the first and the second lateral side is particularly preferably designed as a cuboid with a height of the first and the second lateral side.
  • the cross- section of the cuboid has half of the joint width in both directions respectively. Due to the offset arrangement of the lateral sides and the spacer element as well as the smaller dimensions of the cube compared to the intersection area up to four spacer elements can be arranged in a form-fitting manner.
  • edge protection all four corner edges, which are particularly prone to damage, are provided with edge protection.
  • connection areas with another surface shape and / or a smaller surface area, where only a partial or no form-fitting of the spacer elements are present in the intersection area.
  • the lateral sides have a smaller width than the joint width.
  • spacer elements of a second perforated board spacer elements of a first perforated board are butt- joined so that in the total width of the spacer elements of the first and the width of the spacer elements of the second perforated board, a joint with a joint width is formed, which is designed in such a manner that an optically uniform appearance is created.
  • up to four spacer elements can be arranged in one intersection area.
  • a width of the spacer elements corresponding to half of the joint width is preferred, whereby the spacer elements of a uniform width dimension of the two lateral sides can be conveniently used.
  • other width ratios of butt-joined lateral sides for example, 30% of the joint width of the width of the first lateral side and 70% of the joint width of the width of the second lateral side, this is less preferred.
  • the spacer elements have alignment devices to enable a relative positioning of a first and a second perforated board to each other while laying butt-joined the spacer elements on each other.
  • the alignment devices on a spacer element on the first lateral side are formed as projections in the form of a bolt, while the second lateral side has a contoured shaped hitching attachment.
  • Projection and hitching attachment can be form-fitting, force- fitting or forced-form-fitting.
  • the arrangement of the spacer elements is done in such a manner that, when looking at the visible side of the perforated board, the spacer elements with projection and hitching attachment are arranged in such a manner that on each face side there is a projection and hitching attachment.
  • the spacer elements with projection and hitching attachment are arranged in such a manner that on each face side there is a projection and hitching attachment.
  • an unmistakable laying pattern is conveniently created, since each spacer element projection of a first perforated board is assigned to a spacer element hitching attachment of a second perforated board. If the lateral side is long enough it is also possible to provide several projections and / or hitching attachments on one lateral side.
  • spacer elements with projections on both lateral sides and the spacer elements with hitching attachments on both lateral sides, however this is less preferred.
  • the alignment devices can be formed as an abutment shoulder arranged on the lateral side of the spacer element.
  • the width of the abutment shoulder cannot be larger than the width of the joint.
  • the width of the abutment shoulder is slightly smaller than the joint width; in particular, a width of the abutment shoulder in the range of 80 to 90% of the joint width is preferred, which avoids tilting.
  • the spacer elements are connected with the perforated board by means of the spacer elements adjacent to the side surfaces and / or by an area at the back. The easiest way of attaching is by means of the face sides, since spacer element and perforated board edge have direct contact surfaces and therefore a direct attachment on the contact surfaces is possible.
  • the spacer elements For a connection via the rear face, the spacer elements have a strap-shaped extension, which is located on the rear side.
  • the spacer elements are preferably made of metal, ideally a stainless metal such as aluminium, or made of a plastic material. Alternatively, the spacer elements may also be made out of a biodegradable material, for example paper, cardboard or wood.
  • the spacer elements can be attached to the perforated board mechanically, for example by screwing, riveting or nailing or adhesively, preferably by gluing.
  • Spacer elements can feature bolts or similar fastening elements, in particular of metal, to enable direct attachment without any further elements. In the same way, self-adhesive coating also permits direct fitting without any further fastening means.
  • the arrangement of the spacer elements is adjusted to the thickness of the perforated board; the spacer elements are set back with regard to the front side.
  • a continuous joint is formed while laying, which can be filled with a filler material, and a visually striking discontinuation of the joint or joints to be filled is excluded by the spacer elements.
  • the spacer elements may be supplied as a p re-fabricated angle.
  • the spacer element is a quad-shaped strip with a V-shaped recess, which enables an angular twisting of the strip and thus a corner edge overlapping arrangement with contact of the lateral sides on the side surfaces.
  • the two lateral sides of the prefabricated angle or the two sections of the block-shaped strip are of the same length.
  • the lateral side length is the length of the lateral side of the right angle to the abutment shoulder. It is also preferred that the length of the lateral sides and each of the two sections of the cuboid-shaped strip is less than 5%, preferably less than 3% of the length of the short side of the surface side of the perforated board.
  • the spacer elements are preferably factory-fitted on a perforated board, because then a corner or corner edge protector is conveniently already provided for the storage and transport of the perforated boards. Indeed, it is also possible to attach the spacer elements to the perforated board while laying, but this is less preferred. While laying, it is also possible to incorporate the spacer elements, in such a manner that they are not firmly fitted on the perforated board, but, for example, the flat strap on the back of the spacer elements is simply inserted between the substructure and rear side of the perforated board, and thus the spacer element is fixed to the corner edge of the laid perforated board. Likewise, spacer elements, which during transport, storage and / or laying have fallen off or are broken can, if necessary, be easily replaced.
  • perforated boards to an optically uniform, "uninterrupted" extensive construction is per se not substantially different from the procedure already known, as long as the spacer elements are factory-fitted. Otherwise they can be secured to the perforated board before the perforated board is attached to the substructure, or even afterwards.
  • At least one other perforated board with its spacer elements is butt-joined to the first perforated board or respectively the spacer elements of the first perforated board and aligned with the hole pattern of the first perforated board. Subsequently, this step is repeated again. Between the adjacent perforated board a joint remains that is filled, in a known manner, with a filler, sanded and finally painted in order to obtain a homogeneous and uniform appearance.
  • the spacer elements may be attached to each perforated board at the same time or one by one. This is especially preferable if the spacer elements are used, which are arranged with a strap- shaped extension on the rear side of the perforated board.
  • the perforated boards based on gypsum are provided as an aligned stack of a predetermined number of perforated boards.
  • the spacer elements are provided pre-assembled on a backing material and the board stack with the arranged spacer elements on the backing material in a corner edge are attached simultaneously so that each of the perforated boards of the board stack in the corner edge has one spacer element and is attached thereto, that is, the two lateral sides are attached to the side surfaces.
  • the spacer elements can be coated on the free surface opposite the backing material with an adhesive, which is optionally covered with a liner, and is removed before the spacer elements are attached to the perforated boards.
  • the backing material is used during storage and transport as an additional protection for the edges of the board stack and is preferably removed only immediately before use of the perforated boards.
  • the adhesion between the backing material should be done in such a way so as to avoid a detachment of spacer elements from the perforated board when removing the backing material.
  • the backing material can be cardboard, Kraft paper, silicone paper, plastic, fleece or fabric.
  • the spacer elements can be supplied as a preformed angle elements or block-shaped strip having a V-shaped notch.
  • the spacer elements on the backing material are supplied as a strip with a V-shaped notch, the arranged strips of the backing material can be attached to the first face sides of the perforated board of the stack of board, to form the corner shape bent around the corner edge and the second section attached to the second face side of the corner edge.
  • Figure 1 shows a perspective view of an inventor's patent perforated board constructed from plaster with spacer elements with a detailed illustration of a first spacer element and the functional interaction of several spacer elements
  • Figure 2 is a perspective view of another inventor's patent perforated board with a detailed view of a second spacer element and the functional interaction of several spacer elements
  • Figure 3 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a third spacer element and the functional interaction of several spacer elements
  • Figure 4 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a fourth spacer element and the functional interaction of several spacer elements
  • Figure 5 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a fifth spacer element and the functional interaction of several spacer elements
  • Figure 6 is a schematic illustration of a process for attaching the spacer elements to the perforated boards and providing the perforated boards for use.
  • Figure 1 shows a perforated board 1 with a front side (2) as a visible side, a rear side (3) (not visible), two short sides (4') and two long face sides (4"), four corner edges (5) and as indicated a pattern of holes (6).
  • the dimension of the board in the example version is 1200 x 2000 x 12.5mm.
  • the overlapping angular spacer elements are attached (10) with two lateral sides (1 1 , 12) and a connecting area (13), which are aligned flush with the rear face (3).
  • the length of the lateral sides (1 1 , 12) is in each case 50mm and 6mm high, so that in a fitted state, a joint is formed in the area of the spacer elements (10) with a depth of approximately half the thickness of the perforated boards.
  • the width of the lateral sides (1 1 , 12) corresponds to the joint width.
  • the connecting area (13) has the shape of an isosceles triangle, so that, when laying in the area of the intersection (14), which through the formed joint created by the two lateral sides, a second spacer element can be arranged on the diagonally opposite board in the corresponding corner, and is form-fitting when laying to the base surface (15) of the connecting area (13) of the first spacer element (10).
  • Figure 2 shows a perspective view of an inventor' patent perforated board 1 with a second spacer element (20), which enables two offset lateral sides (21 , 22) with a width corresponding to the joint width.
  • the connecting area (23) between the first lateral side (21 ) and second lateral side (22) is carried out as a cuboid (24) with a height of the first and second lateral side (21 , 22).
  • the cross- section of the cuboid (23) has half of the joint width in both directions respectively. Due to the offset arrangement of the lateral sides (21 , 22) of the spacer elements (20) and the dimensions of the cuboid (24) up to the four spacer elements can be arranged in a form-fitting manner in the intersection area (14). Thus, all four corner edges, which are particularly prone to damage (5), are provided with edge protection.
  • Figure 3 shows a perspective view of an inventor's patent perforated board 1 with a third spacer element (30) with two lateral sides (31 , 32) and a connecting area (33), which is arranged on all four corner edges of the inventor's patent perforated board 1.
  • the width of the spacer elements (30) and respectively the lateral sides (31 , 32) is adapted to the hole patterns (6) and has in the example version half of the joint width, so that in a fitted state, where respectively for every two spacer elements adjacent boards are arranged butt-joined, an optically uniform appearance is ensured.
  • the connecting area (33) results in an extension of the two lateral sides (31 , 32), and is shaped as a cuboid with a small rounding.
  • each spacer element (30) as aligning device has a bolt-shaped projection (34) on a lateral side (31 ) and on the second lateral side (32) a force-fitted or friction-locked hitching attachment (35).
  • a bolt-shaped projection (34) and hitching attachment (35) is arranged respectively, so that from the perspective of the visible side (2) a recurring pattern is formed, creating a confusion-free laying, which in the image is given by the interlocking interaction of the bolt-shaped projection (34) and the hitching attachment (35).
  • spacer elements (30) of four inventor's patent perforated boards 1 can be aligned in an intersection area (14) and are forced-fittingly attached.
  • the arrangement of the spacer elements (30) thus allows the convenient application of the spacer elements (30) on all four corners of an inventor's patent perforated board 1 , so that all four corner edges are protected.
  • spacer elements (10, 20, 30) are attached in the example versions with an adhesive that is not shown, and listed as an injection (spray) mould made out of plastic, in particular PE or PP.
  • the spacer elements (30) are already factory-fitted on the perforated board. But it is also possible to attach the spacer elements (30) prior to laying, or even during the process of laying the perforated boards.
  • Figure 4 shows a fourth version of the inventor's patent perforated board, which differs only in the type of spacer elements (40) of the version in Figure 3, namely in the actual arrangement of the alignment device.
  • the spacer elements (40) include a free lateral side (41 ) and a lateral side (42) with a connecting area (43), where an alignment device in the form of an abutment shoulder (44) is arranged on the lateral side (42).
  • the abutment shoulder (44) has 1.8 times the width of the lateral side (41 ), i.e. its width is 90% of the joint width.
  • both lateral sides (41 , 42) have the same length.
  • the spacer elements (40) in the example version are made out of metal. Also in this example version, the spacer elements (40) are already factory fitted, but can also be fitted on site.
  • Figure 5 shows a fifth version of the inventor's patent perforated board, which, according to the version in Figure 3, only differs in regards to the type of the spacer elements used (50).
  • the spacer elements (50) are formed as a quad-shaped strip made of two bars (51 , 52) and a centrally arranged V-shaped recess (53).
  • This V-shaped recess (53) allows a bending of the spacer element (50) to the base point (54) of the V-shaped recess (53) for forming the angular shape.
  • the base point (54) and the form-fitting abutting lateral sides (51 , 52) form the connecting area (55).
  • the spacers (50) have no alignment devices, however, these can be provided.
  • the spacer element (50) is produced as injection moulding made from a plastic material, preferably of PE or PP and fixed with an adhesive, which is not shown here. As already described in the other example versions above, the spacer elements (50) may be factory fitted or attached later.
  • Figure 6 shows a schematic representation of a process for attaching the spacer elements (10, 20, 30, 40, 50) to the perforated board.
  • Image 1 shows a pre-fabricated semi-manufactured product (60) consisting of a backing material (61 ) on a cardboard base, on which angled spacer elements (62) are arranged with adhesive on a grid, which corresponds to the number and thickness of the perforated boards (63) in a board stack (64).
  • angles are made of a PE material with a height of 6mm each, which corresponding to the perforated boards (63) with a thickness of 12.5mm are arranged on the backing material at a distance of 6.5mm and on the opposing free side of backing the two lateral sides of the angle (62) are coated with an adhesive.
  • the semi-manufactured products (60) are attached one after the other or simultaneously, in the corner edges (65) of the stack of boards (64), which is indicated by the arrow in the sub-image 2 so that the angle (62) can be glued by means of an adhesive on the free surface of the board stack (64).
  • the semi-manufactured product (60) is positioned in such a manner that the angles (62) are flush with the back of the perforated boards, so that while laying a continuous joint is formed, which can be filled with a filling material, and a visually striking discontinuation of the joint or joints to be filled is excluded by the spacer elements.
  • Sub-image 3 shows part of the stack of board (64) as a transport unit of the inventor's patent perforated boards (63) equipped with spacer elements (62), which may be wrapped with a protective film (not shown here) on a pallet.
  • spacer elements 62
  • other packaging materials are possible, for instance, a cardboard packaging for the stack of boards (64) with pallet can be provided.
  • the stack of board has a double-edge protection which is made up of the first inner layers of the spacer elements arranged around the comers and the second, outer layer of the backing material.
  • the easy-peel backing material 21 is removed (sub-image 4), whereby the spacer elements and angles (62) are still firmly attached to the individual perforated boards (63), as shown in the extract.
  • the perforated boards (63) can now be removed individually from the stack of boards (64) for use.
  • spacer elements to the perforated boards of the stack boards mechanically, for example by barbs, bolts or staples.
  • a quad-shaped spacer element (50) with a notch as a predetermined bend, which is arranged on a flat backing material can in accordance with the fifth version also be used.
  • the folding of the semi manufactured product (60) to form the angular shape of the spacer elements (50) can then be performed as a step before the actual attachment, i.e. the semi-manufactured product (50) is attached in angular form to the board stack.
  • the folding can also take place while sticking the semi-manufactured product to the stack of boards, in that the first half of semi-manufactured product is attached to the stack of boards, bent and then the second half is attached.
  • the backing material (61 ) can be provided with attached spacer elements as semi-manufactured product in a rolled form, and a strip with the required number of spacer elements can be cut to length for the role prior to the attachment to the stack of boards.
  • the spacer elements of a preferred corner can be in a different colour to the rest of the spacer elements.
  • all the boards of a board stack in which, when viewed from above, the perforated boards are all arranged in the same orientation, the spacer elements used in a specific corner edge can be coloured red, while the other spacer elements are colourless.
  • the perforated board is aligned in such a manner that the coloured spacer element is always in the same comer, approximately the bottom left. As a result a uniform laying direction is guaranteed.

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  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
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Abstract

Perforated boards based on gypsum, in particular perforated gypsum plasterboards or perforated gypsum fibreboards, are provided with angle-shaped spacer elements that allow the boards to be formed easily into a ceiling or wall, through the creation of a fixed predetermined gap width between adjacent perforated boards.

Description

Perforated boards based on gypsum and methods used for laving
The invention relates to a perforated board based on gypsum and a method for laying on a substructure, in particular for constructing a suspended ceiling or a wall, whereby the joints between the individual perforated boards are filled by means of a filler and then smoothly sanded. Furthermore, the invention relates to a method for manufacturing such perforated boards.
Such perforated boards based on gypsum, particularly plasterboards and gypsum fibre perforated boards are primarily used as suspended ceilings in large rooms, but also for wall structures, amongst other things for improving room acoustics. These perforated boards usually have a gridlike, regular hole pattern. The costs for such constructions essentially depend on a quick and thereby cheap fitting.
The time required for the fitting of perforated boards as well as the personnel expenses are determined significantly by the time required for the precise alignment of the perforated boards. Variations in the spacing of the holes on the joints between single boards or variations in the fitting of a non-parallel alignment are clearly apparent due to the hole pattern. To this end, in each case, tools are used which are adapted to the spacing of the holes of the perforated boards and, by forming a joint between the adjacent perforated boards, a uniform appearance can be ensured. The joint is filled with filling material and then smoothly sanded. However, at least two people are needed for the alignment of the boards, which has a negative impact on the costs.
In order to improve the current state-of-the-art technology, a number of solutions have been proposed, in particular, based on the use of particularly dimensionally stable perforated boards, for example, a production method on an industrial scale as described in EP 1369215 A1.
EP 1369215 A1 describes in the following a ceiling construction with perforated boards, which are manufactured in such a manner, that the boards are laid closely adjacent to one another, so that only a slim joint remains visible. In principle, the laying of these boards is much easier; however, there are two main disadvantages. Due to the missing joint area, an adaptation to the varying thicknesses of adjacent boards is not possible. Furthermore, the edges are exposed to an increased risk of damage which, even in cases of minor damage, leads to visible impairments of the fine joints, which subsequently can only be remedied with costly repairs before the final painting of the ceiling. In addition, the fine joints only dispose of a limited joint resistance. WO 2005/059267 A1 tries to avoid the drawback with regard to the lack of the possibility of adaptation of the same applicant, in that the plasterboards are laid with a relatively small joint width, preferably adjoining, and that a cover strip is applied on the joints. After the application of a filling emulsion paint, the cover strips are levelled out by sanding, so that they are no longer visible after the final painting. Due to the lack of filling the joint between adjoining boards with joint filling material, the disadvantage of the limited joint resistance persists.
WO 2006/067213 A1 likewise reveals a particularly dimensionally stable perforated board based on gypsum, of which at least two face sides are rabbet edged. When fitting the boards this is done in such a manner that the boards are laid closely adjacent to each other, and a perforated board having a side with rabbet edge meets a side without rabbet edge so that a room-facing joint remains. The resulting joint can be filled in a conventional manner with a filler or filler material. Due to the rear end finishing of the joint, the filler material cannot leak out of the joint, so that the joining is much easier and is supposedly more durable. Whilst abandoning this advantage, provisions are made that the rabbet edge is not formed over the entire length of an edge, but can also be used in whole or in part. In such a case, the remaining rabbet edge can be reduced by 10% of the respective edge length, which is sufficient for facilitating the alignment. For commercially perforated boards measuring about 1200 x 2000mm, this means that with two stop ridges on the face edge, a minimum length of 60mm must be maintained, as shorter dimensions can increase risk of damage, such as the snapping off of the stop ridges during transport, storage and processing, since they are made of plaster. Although WO 2006/067213 A1 is an improvement with regard to state-of-the-art technology, the production of perforated boards with rabbet edge is relatively complicated and expensive, especially the perforated boards with partially offset rabbet edge.
It is known from DE 10 2010 026 602 A1 that there is a perforated board based on gypsum on which the mechanically or adhesively fastened spacer (distance) elements are made from a different material, and that the total length of all on one face side arranged spacer elements do not exceed 5% of the length of the face side. The spacer elements are constructed in order of width, so that the resulting joint width between two reveals a uniform pattern created by spacer elements at perforated board intervals.
All these solutions show different approaches for how to reduce the time required for the alignment of perforated boards based on gypsum. A common feature of the solutions is that they require very dimensionally stable boards. These boards have the disadvantage that the corners are particularly prone to damage as well as their connecting corner edges, so that high demands are placed on the handling and transport of these boards. However, DE 10 2010 06626 reveals a cross-shaped spacer element, which is located in a corner, and supposedly provides some protection against damage. Yet, in practice, it appears that the protruding ridges sometimes even may cause damage to the corners when force is applied due to the leverage. As practice-oriented corner protection, the cross-shaped spacer elements are not suitable, since the protruding ridges themselves are prone to breakage.
Based on the state-of-the-art technology, the invention sets the task of providing a perforated board based on gypsum which overcomes the disadvantages of state-of-the-art technology, and has a practice-oriented protection against damage during handling and transport, and at the same time is simple and inexpensive to manufacture. Further, the task of the invention is also to provide a method for laying the perforated boards and a method for manufacturing them.
The first task is achieved by a perforated board based on gypsum with the features of claim 1. The second task is achieved by a method with regard to the laying of the inventor's patent perforated boards with features of claim 15. The third task is achieved by a method with features of claim 16. Independent protection is claimed for a stack of boards with the features of claim 16, a semi-finished product with the features of claim 22, a kit with the features of claim 23 and a method for the construction of ceilings and walls, using a kit according to claim 23 with the features of claim 24. Preferred versions are subject matter of the respective sub claims.
The inventor's patent perforated board based on gypsum having a front and a rear side and four side faces, which form four corner edges, spacer elements in the form of an angle with two lateral (arm) sides and a connecting joint area, which connects one of the two lateral sides, which overlaps a corner edge and whose lateral sides rest on the corner edge of the adjacent face sides.
The solution sets out from the idea of using a particularly dimensionally stable perforated board in order to avoid the complex manufacture and costly measure of whole or partial rabbeting. Instead, prefabricated spacer elements are arranged on a perforated board, whereby the laying of the spacer elements of a second perforated board can be butt-joined to a first perforated board, so that the width of the spacer elements forms a gap with a gap width, which is designed in such a manner that an optically uniform appearance is created. Through the angular arrangement of the spacer elements on the particular damage-vulnerable corner edge, the spacer element provides, apart from the size-adjusted joint width, a corner and corner edge protection against mechanical damage. The connection area between the two lateral sides is designed in such a manner that the arrangement of the connecting area allows at least one further spacer element in the area, which is formed by the overlapping area of the two mutually orthogonal joints in two adjacent side faces of the perforated board, in whose corner the spacer elements are arranged. The overlapping area hereinafter referred to as the intersection area is rectangular, in particular square, since usually both joints have the same width. Through an appropriate choice of material, the spacer elements can be kept small in size, since damages such as snapping off and the resulting loss of adjustability as in the case of plaster are not to be expected. Furthermore, for the formation of a high joint strength, the entire side face or edge of each adjacent perforated board is practically available as an adhesive base for the filling material.
In a first version, the lateral sides of the spacer elements have a width corresponding to the joint width. The lateral sides touch each other along one edge and are connected by a connecting area. The connecting area has an area in the angular level within the cross-section of no more than half the area of the intersection area. At least two spacer elements are arranged in diagonally opposite corners, per perforated board. Also four spacer elements in all four corners can be arranged, whereby the spacer elements of the second diagonally opposite corners are vertically offset at least in the height of the lateral sides or of the spacer elements of the second diagonally opposite corners, so that, when fitting the four spacer elements, these are arranged in an intersection area in the form of two vertically offset levels with two elements. In a particularly preferred version, the connecting area in the form of an isosceles triangle with a lateral (arm) side length of the triangle corresponding to the gap width, so that in the intersection area, two diagonally offset spacer elements are form- fitted (inter-locked), with the ability to be arranged with its connecting area. Alternatively, it is also possible to provide connection areas with another surface shape and / or a smaller surface, where only a partial or no form-fitting of the spacer elements are present in the intersection area.
In a second version, the lateral sides of the spacer element have a width corresponding to the gap width and are offset vertically by at least the height of the lateral sides. The connecting area has an area in the angular level within the cross-section of no more than a quarter of the area of the intersection area. The connection area between the first and the second lateral side is particularly preferably designed as a cuboid with a height of the first and the second lateral side. The cross- section of the cuboid has half of the joint width in both directions respectively. Due to the offset arrangement of the lateral sides and the spacer element as well as the smaller dimensions of the cube compared to the intersection area up to four spacer elements can be arranged in a form-fitting manner. Thus, all four corner edges, which are particularly prone to damage, are provided with edge protection. Alternatively, it is also possible to provide connection areas with another surface shape and / or a smaller surface area, where only a partial or no form-fitting of the spacer elements are present in the intersection area. In a third version, the lateral sides have a smaller width than the joint width. In this case, while laying spacer elements of a second perforated board, spacer elements of a first perforated board are butt- joined so that in the total width of the spacer elements of the first and the width of the spacer elements of the second perforated board, a joint with a joint width is formed, which is designed in such a manner that an optically uniform appearance is created. Also, in this case, up to four spacer elements can be arranged in one intersection area. Thus, all four corner edges, which are particularly prone to damage, are provided with edge protection.
In the third version, a width of the spacer elements corresponding to half of the joint width is preferred, whereby the spacer elements of a uniform width dimension of the two lateral sides can be conveniently used. Although it is also possible to choose other width ratios of butt-joined lateral sides, for example, 30% of the joint width of the width of the first lateral side and 70% of the joint width of the width of the second lateral side, this is less preferred.
In a preferred version of the third version, the spacer elements have alignment devices to enable a relative positioning of a first and a second perforated board to each other while laying butt-joined the spacer elements on each other. Preferably, the alignment devices on a spacer element on the first lateral side are formed as projections in the form of a bolt, while the second lateral side has a contoured shaped hitching attachment. Projection and hitching attachment can be form-fitting, force- fitting or forced-form-fitting. Preferably, the arrangement of the spacer elements is done in such a manner that, when looking at the visible side of the perforated board, the spacer elements with projection and hitching attachment are arranged in such a manner that on each face side there is a projection and hitching attachment. In this case, with point-symmetrical perforated boards an unmistakable laying pattern is conveniently created, since each spacer element projection of a first perforated board is assigned to a spacer element hitching attachment of a second perforated board. If the lateral side is long enough it is also possible to provide several projections and / or hitching attachments on one lateral side.
Although it is also possible to use spacer elements with projections on both lateral sides and the spacer elements with hitching attachments on both lateral sides, however this is less preferred.
In an alternative version, the alignment devices can be formed as an abutment shoulder arranged on the lateral side of the spacer element. The width of the abutment shoulder cannot be larger than the width of the joint. Preferably, the width of the abutment shoulder is slightly smaller than the joint width; in particular, a width of the abutment shoulder in the range of 80 to 90% of the joint width is preferred, which avoids tilting. The spacer elements are connected with the perforated board by means of the spacer elements adjacent to the side surfaces and / or by an area at the back. The easiest way of attaching is by means of the face sides, since spacer element and perforated board edge have direct contact surfaces and therefore a direct attachment on the contact surfaces is possible. For a connection via the rear face, the spacer elements have a strap-shaped extension, which is located on the rear side.
The spacer elements are preferably made of metal, ideally a stainless metal such as aluminium, or made of a plastic material. Alternatively, the spacer elements may also be made out of a biodegradable material, for example paper, cardboard or wood.
The spacer elements can be attached to the perforated board mechanically, for example by screwing, riveting or nailing or adhesively, preferably by gluing. Spacer elements can feature bolts or similar fastening elements, in particular of metal, to enable direct attachment without any further elements. In the same way, self-adhesive coating also permits direct fitting without any further fastening means.
Preferably, the arrangement of the spacer elements is adjusted to the thickness of the perforated board; the spacer elements are set back with regard to the front side. As a result, a continuous joint is formed while laying, which can be filled with a filler material, and a visually striking discontinuation of the joint or joints to be filled is excluded by the spacer elements.
The spacer elements may be supplied as a p re-fabricated angle. Alternatively, in the case of the third version, it is also possible that the spacer element is a quad-shaped strip with a V-shaped recess, which enables an angular twisting of the strip and thus a corner edge overlapping arrangement with contact of the lateral sides on the side surfaces. Preferably, the two lateral sides of the prefabricated angle or the two sections of the block-shaped strip are of the same length. In the case of the arrangement of the aligning device as an abutment shoulder, the lateral side length is the length of the lateral side of the right angle to the abutment shoulder. It is also preferred that the length of the lateral sides and each of the two sections of the cuboid-shaped strip is less than 5%, preferably less than 3% of the length of the short side of the surface side of the perforated board.
The spacer elements are preferably factory-fitted on a perforated board, because then a corner or corner edge protector is conveniently already provided for the storage and transport of the perforated boards. Indeed, it is also possible to attach the spacer elements to the perforated board while laying, but this is less preferred. While laying, it is also possible to incorporate the spacer elements, in such a manner that they are not firmly fitted on the perforated board, but, for example, the flat strap on the back of the spacer elements is simply inserted between the substructure and rear side of the perforated board, and thus the spacer element is fixed to the corner edge of the laid perforated board. Likewise, spacer elements, which during transport, storage and / or laying have fallen off or are broken can, if necessary, be easily replaced.
The laying of perforated boards to an optically uniform, "uninterrupted" extensive construction is per se not substantially different from the procedure already known, as long as the spacer elements are factory-fitted. Otherwise they can be secured to the perforated board before the perforated board is attached to the substructure, or even afterwards. At least one other perforated board with its spacer elements is butt-joined to the first perforated board or respectively the spacer elements of the first perforated board and aligned with the hole pattern of the first perforated board. Subsequently, this step is repeated again. Between the adjacent perforated board a joint remains that is filled, in a known manner, with a filler, sanded and finally painted in order to obtain a homogeneous and uniform appearance.
The spacer elements may be attached to each perforated board at the same time or one by one. This is especially preferable if the spacer elements are used, which are arranged with a strap- shaped extension on the rear side of the perforated board.
When using spacer elements without such strap-like extension, an alternative method for attaching the spacer elements can be used. For this purpose, the perforated boards based on gypsum are provided as an aligned stack of a predetermined number of perforated boards. The spacer elements are provided pre-assembled on a backing material and the board stack with the arranged spacer elements on the backing material in a corner edge are attached simultaneously so that each of the perforated boards of the board stack in the corner edge has one spacer element and is attached thereto, that is, the two lateral sides are attached to the side surfaces. For this purpose, the spacer elements can be coated on the free surface opposite the backing material with an adhesive, which is optionally covered with a liner, and is removed before the spacer elements are attached to the perforated boards. The backing material is used during storage and transport as an additional protection for the edges of the board stack and is preferably removed only immediately before use of the perforated boards. By selecting a suitable adhesive, the adhesion between the backing material should be done in such a way so as to avoid a detachment of spacer elements from the perforated board when removing the backing material. Alternatively, it is also possible to attach the spacer elements to the board mechanically, for example by screwing, riveting or nailing. In both cases, it may be necessary to pre-treat the side surfaces of the perforated boards with a primer to enhance the adhesion of the adhesive on the plaster.
The backing material can be cardboard, Kraft paper, silicone paper, plastic, fleece or fabric.
Depending on the apparatus arrangement, it is possible, to attach the corner edges of the stack of boards in succession or several simultaneously, in particular all four comer edges with spacer elements on the pre-assembled backing material strip.
The spacer elements can be supplied as a preformed angle elements or block-shaped strip having a V-shaped notch. Provided that the spacer elements on the backing material are supplied as a strip with a V-shaped notch, the arranged strips of the backing material can be attached to the first face sides of the perforated board of the stack of board, to form the corner shape bent around the corner edge and the second section attached to the second face side of the corner edge.
Preferred versions will be described below with reference to the drawings, wherein like reference characters (numbers) designate like items. Demonstrated here:
Figure 1 shows a perspective view of an inventor's patent perforated board constructed from plaster with spacer elements with a detailed illustration of a first spacer element and the functional interaction of several spacer elements
Figure 2 is a perspective view of another inventor's patent perforated board with a detailed view of a second spacer element and the functional interaction of several spacer elements
Figure 3 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a third spacer element and the functional interaction of several spacer elements
Figure 4 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a fourth spacer element and the functional interaction of several spacer elements
Figure 5 is a perspective view of a third version of an inventor's patent perforated board with a detailed view of a fifth spacer element and the functional interaction of several spacer elements
Figure 6 is a schematic illustration of a process for attaching the spacer elements to the perforated boards and providing the perforated boards for use. Figure 1 shows a perforated board 1 with a front side (2) as a visible side, a rear side (3) (not visible), two short sides (4') and two long face sides (4"), four corner edges (5) and as indicated a pattern of holes (6). The dimension of the board in the example version is 1200 x 2000 x 12.5mm. On two opposite corner edges (5) the overlapping angular spacer elements are attached (10) with two lateral sides (1 1 , 12) and a connecting area (13), which are aligned flush with the rear face (3). The length of the lateral sides (1 1 , 12) is in each case 50mm and 6mm high, so that in a fitted state, a joint is formed in the area of the spacer elements (10) with a depth of approximately half the thickness of the perforated boards.
In this example version, the width of the lateral sides (1 1 , 12) corresponds to the joint width. In plan view, the connecting area (13) has the shape of an isosceles triangle, so that, when laying in the area of the intersection (14), which through the formed joint created by the two lateral sides, a second spacer element can be arranged on the diagonally opposite board in the corresponding corner, and is form-fitting when laying to the base surface (15) of the connecting area (13) of the first spacer element (10).
Figure 2 shows a perspective view of an inventor' patent perforated board 1 with a second spacer element (20), which enables two offset lateral sides (21 , 22) with a width corresponding to the joint width. The connecting area (23) between the first lateral side (21 ) and second lateral side (22) is carried out as a cuboid (24) with a height of the first and second lateral side (21 , 22). The cross- section of the cuboid (23) has half of the joint width in both directions respectively. Due to the offset arrangement of the lateral sides (21 , 22) of the spacer elements (20) and the dimensions of the cuboid (24) up to the four spacer elements can be arranged in a form-fitting manner in the intersection area (14). Thus, all four corner edges, which are particularly prone to damage (5), are provided with edge protection.
Figure 3 shows a perspective view of an inventor's patent perforated board 1 with a third spacer element (30) with two lateral sides (31 , 32) and a connecting area (33), which is arranged on all four corner edges of the inventor's patent perforated board 1. The width of the spacer elements (30) and respectively the lateral sides (31 , 32) is adapted to the hole patterns (6) and has in the example version half of the joint width, so that in a fitted state, where respectively for every two spacer elements adjacent boards are arranged butt-joined, an optically uniform appearance is ensured. The connecting area (33) results in an extension of the two lateral sides (31 , 32), and is shaped as a cuboid with a small rounding. Further, each spacer element (30) as aligning device has a bolt-shaped projection (34) on a lateral side (31 ) and on the second lateral side (32) a force-fitted or friction-locked hitching attachment (35). On each side surface (4', 4"), a bolt-shaped projection (34) and hitching attachment (35) is arranged respectively, so that from the perspective of the visible side (2) a recurring pattern is formed, creating a confusion-free laying, which in the image is given by the interlocking interaction of the bolt-shaped projection (34) and the hitching attachment (35).
Due to geometric circumstances, four spacer elements (30) of four inventor's patent perforated boards 1 can be aligned in an intersection area (14) and are forced-fittingly attached. The arrangement of the spacer elements (30) thus allows the convenient application of the spacer elements (30) on all four corners of an inventor's patent perforated board 1 , so that all four corner edges are protected.
The spacer elements (10, 20, 30) are attached in the example versions with an adhesive that is not shown, and listed as an injection (spray) mould made out of plastic, in particular PE or PP.
In addition to the dimensionally accurate joint width, i.e. overall visually appealing impression, the corners and the corner edges are effectively protected against damage due to an angular, corner edge (5) overlapping arrangement.
In the example version, the spacer elements (30) are already factory-fitted on the perforated board. But it is also possible to attach the spacer elements (30) prior to laying, or even during the process of laying the perforated boards.
Figure 4 shows a fourth version of the inventor's patent perforated board, which differs only in the type of spacer elements (40) of the version in Figure 3, namely in the actual arrangement of the alignment device. The spacer elements (40) include a free lateral side (41 ) and a lateral side (42) with a connecting area (43), where an alignment device in the form of an abutment shoulder (44) is arranged on the lateral side (42). In the example version the abutment shoulder (44) has 1.8 times the width of the lateral side (41 ), i.e. its width is 90% of the joint width. The interaction of two spacer elements (40) while laying can be seen in the detail view, where the free lateral side (41 ) touches the abutment shoulder (44), which is arranged on the lateral side (42). Also in this case, both lateral sides (41 , 42) have the same length.
Even with the spacer elements (40) four corners of four inventor's patent perforated boards (1 ) can be arranged conveniently in an intersection area (1 1 ) and be partially form-fittingly attached together with the exception of the area of the rounding, so that the spacer elements may be arranged conveniently on all four corner edges (5) of the perforated boards and provide corner protection.
The spacer elements (40) in the example version are made out of metal. Also in this example version, the spacer elements (40) are already factory fitted, but can also be fitted on site.
Figure 5 shows a fifth version of the inventor's patent perforated board, which, according to the version in Figure 3, only differs in regards to the type of the spacer elements used (50). In this case, the spacer elements (50) are formed as a quad-shaped strip made of two bars (51 , 52) and a centrally arranged V-shaped recess (53). This V-shaped recess (53) allows a bending of the spacer element (50) to the base point (54) of the V-shaped recess (53) for forming the angular shape. The base point (54) and the form-fitting abutting lateral sides (51 , 52) form the connecting area (55).
In the example version, the spacers (50) have no alignment devices, however, these can be provided.
The spacer element (50) is produced as injection moulding made from a plastic material, preferably of PE or PP and fixed with an adhesive, which is not shown here. As already described in the other example versions above, the spacer elements (50) may be factory fitted or attached later.
Figure 6 shows a schematic representation of a process for attaching the spacer elements (10, 20, 30, 40, 50) to the perforated board. Image 1 shows a pre-fabricated semi-manufactured product (60) consisting of a backing material (61 ) on a cardboard base, on which angled spacer elements (62) are arranged with adhesive on a grid, which corresponds to the number and thickness of the perforated boards (63) in a board stack (64). In the example version the angles are made of a PE material with a height of 6mm each, which corresponding to the perforated boards (63) with a thickness of 12.5mm are arranged on the backing material at a distance of 6.5mm and on the opposing free side of backing the two lateral sides of the angle (62) are coated with an adhesive. The semi-manufactured products (60) are attached one after the other or simultaneously, in the corner edges (65) of the stack of boards (64), which is indicated by the arrow in the sub-image 2 so that the angle (62) can be glued by means of an adhesive on the free surface of the board stack (64). Hereby, the semi-manufactured product (60) is positioned in such a manner that the angles (62) are flush with the back of the perforated boards, so that while laying a continuous joint is formed, which can be filled with a filling material, and a visually striking discontinuation of the joint or joints to be filled is excluded by the spacer elements. Sub-image 3 shows part of the stack of board (64) as a transport unit of the inventor's patent perforated boards (63) equipped with spacer elements (62), which may be wrapped with a protective film (not shown here) on a pallet. Alternatively, other packaging materials are possible, for instance, a cardboard packaging for the stack of boards (64) with pallet can be provided. As a particular advantage, the stack of board has a double-edge protection which is made up of the first inner layers of the spacer elements arranged around the comers and the second, outer layer of the backing material. Immediately before use of the perforated boards (64) the easy-peel backing material 21 is removed (sub-image 4), whereby the spacer elements and angles (62) are still firmly attached to the individual perforated boards (63), as shown in the extract. The perforated boards (63) can now be removed individually from the stack of boards (64) for use.
Alternatively, it is also possible to attach the spacer elements to the perforated boards of the stack boards mechanically, for example by barbs, bolts or staples.
Instead of the spacer element shown here in the form of an angle (62) a quad-shaped spacer element (50) with a notch as a predetermined bend, which is arranged on a flat backing material can in accordance with the fifth version also be used. The folding of the semi manufactured product (60) to form the angular shape of the spacer elements (50) can then be performed as a step before the actual attachment, i.e. the semi-manufactured product (50) is attached in angular form to the board stack. Alternatively, the folding can also take place while sticking the semi-manufactured product to the stack of boards, in that the first half of semi-manufactured product is attached to the stack of boards, bent and then the second half is attached.
In the case of the spacer elements (50), the backing material (61 ) can be provided with attached spacer elements as semi-manufactured product in a rolled form, and a strip with the required number of spacer elements can be cut to length for the role prior to the attachment to the stack of boards.
In order to achieve a uniform visual appearance with regard to certain perforated board patterns it is important to pay attention to the correct joint width and observe the direction of laying. To simplify laying and avoid mistakes while laying the spacer elements of a preferred corner can be in a different colour to the rest of the spacer elements. For example, all the boards of a board stack in which, when viewed from above, the perforated boards are all arranged in the same orientation, the spacer elements used in a specific corner edge can be coloured red, while the other spacer elements are colourless. While laying, the perforated board is aligned in such a manner that the coloured spacer element is always in the same comer, approximately the bottom left. As a result a uniform laying direction is guaranteed. It is of course obvious to the expert that the dimensions shown in the example version only have illustrative character and do not limit the subject matter of the invention in any way. In particular, the expert is aware that the external dimensions of the perforated board depend on each specific hole pattern, in practice with a dimension of about 1200 x 2000mm.

Claims

Claims
1 . Perforated board (1 , 63) based on gypsum, in particular a perforated gypsum plasterboard or perforated gypsum fibreboard, comprising a front side (2) and a rear side (3), four side faces (4', 4") and four corner edges (5) and comprising spacer elements (10, 20, 30, 40, 50, 62) made from a different material than the material of the perforated board (1 ) on at least two side faces (4', 4") for laying in a formation so as to form a joint having a joint width corresponding to the width of the spacer elements (10, 20, 30, 40, 50, 62), characterised in that the spacer elements (10, 20, 30, 40, 50, 62) have the shape of a bracket with two legs (1 1 , 12, 21 , 22, 31 , 32, 41 , 42, 51 , 52) and a connecting region (13, 23, 33, 43, 55) connecting the legs (1 1 , 12, 21 , 22, 31 , 32, 41 , 42, 51 , 52), are arranged so as to engage over a corner edge (5) and the legs (1 1 , 12, 21 , 22, 31 , 32, 41 , 42, 51 , 52) bear against the two side faces (4', 4") adjoining the corner edge (5).
2. Perforated board (1 , 63) according to claim 1 , characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are arranged on at least 2 corner edges (5).
3. Perforated board (1 , 63) according to claim 1 or 2, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are arranged on all 4 corner edges (5).
4. Perforated board (1 , 63) according to one of claims 1 to 3, characterised in that the connecting region (13, 23, 33, 43, 55) has a smaller surface area than the intersection (14) between two joints.
5. Perforated board (1 , 63) according to one of claims 1 to 4, characterised in that the connecting region (13, 23, 33, 43, 55) has at most half the surface area of the intersection (14).
6. Perforated board (1 , 63) according to one of claims 1 to 4, characterised in that the connecting region (13, 23, 33, 43, 55) has at most a quarter of the surface area of the intersection (14).
7. Perforated board (1 , 63) according to one of claims 1 to 6, characterised in that the connecting region (13, 23, 33, 43, 55) has the shape of an isosceles triangle or a square.
8. Perforated board (1 , 63) according to one of claims 1 to 7, characterised in that the legs (1 1 , 12, 21 , 22, 31 , 32, 41 , 42, 51 , 52) have a smaller width than the joint width, particularly preferably half the joint width.
9. Perforated board (1 , 63) according to one of claims 1 to 8, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) have positioning means (34, 35, 44).
10. Perforated board (1 , 63) according to claim 9, characterised in that the positioning means (34, 35, 44) are configured as form-fitting, force-fitting or force- and form- fitting protrusions and openings or as stop shoulders.
1 1 . Perforated board (1 , 63) according to one of claims 1 to 10, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are formed from metal, in particular stainless metal, or from plastic material.
12. Perforated board (1 , 63) according to one of claims 1 to 1 1 , characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are attached to the board mechanically or adhesively, preferably by glue.
13. Perforated board (1 ) according to one of claims 1 to 12, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are set back with respect to the front side (2) of the perforated board (1 ).
14. Perforated board (1 ) according to one of claims 1 to 13, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are fitted at the factory.
15. Method for laying perforated boards (1 ) based on gypsum according to at least one of claims 1 to 14, wherein perforated boards (1 ) with spacer elements (10, 20, 30, 40, 50, 62) are butted against one another so as to form a joint, and then the joints between the boards are filled with a filling material.
16. Method for fitting the spacer elements on a perforated board (1 , 63) based on gypsum according to one of claims 1 to 14, characterised in that the perforated boards (1 , 63) are provided as an aligned board stack (64) composed of a predefined number of perforated boards, a plurality of spacer elements are provided on a carrier material (61 ) as a semi-finished product (60), and the board stack (64) is connected in a corner edge region (65) to the spacer elements (10, 20, 30, 40, 50, 62) arranged on the carrier material (61 ), so that each individual perforated board (1 , 63) of the board stack (64) has a spacer element (10, 20, 30, 40, 50, 62) in the corner edge (65).
17. Method according to claim 16, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are coated with a glue on the free surface opposite the carrier material (61 ).
18. Method according to claim 16 or 17, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are provided as rectangular strips (50) having a V-shaped notch (53) and, prior to or during fitting on the perforated board stack (64), the strips (50) are bent together with the carrier material (61 ) so as to create the bracket shape and bearing attachment to the side faces forming a corner edge (65).
19. Method according to claim 18, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) on the carrier material (61 ) are provided in rolled-up form, from which the required number of spacer elements can be cut as a semi-finished product (60).
20. Method according to one of claims 16 to 19, characterised in that the spacer elements (10, 20, 30, 40, 50, 62) are fitted on multiple, in particular on all four, corner edges (65) of the board stack (64) simultaneously.
21 . Board stack (64) composed of a plurality of perforated boards (1 , 63) with spacer elements (10, 20, 30, 40, 50, 62) as edge protection in the corners of the perforated boards, which spacer elements are optionally arranged on a carrier material (61 ), and the board stack is preferably wrapped with a film material or packaged using other means.
22. Semi-finished product (60) composed of a carrier material (61 ) and a plurality of spacer elements (10, 20, 30, 40, 50, 62) arranged on the carrier material (61 ), preferably using a glue, for fitting the spacer elements (10, 20, 30, 40, 50, 62) on a perforated board based on gypsum (1 , 63).
23. Kit for a suspended ceiling or a clad wall made from perforated boards according to one of claims 1 to 14, composed of a plurality of perforated boards (1 , 63) and a plurality of spacer elements (10, 20, 30, 40, 50, 62).
24. Method for constructing a suspended ceiling or a clad wall using the kit according to claim 23, wherein spacer elements (10, 20, 30, 40, 50, 62) are fitted in the corner edges (5, 65) of the perforated boards at the site of fabrication.
EP14714238.4A 2013-03-28 2014-03-27 Perforated boards based on gypsum and methods used for laying Active EP2978908B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL14714238T PL2978908T3 (en) 2013-03-28 2014-03-27 Perforated boards based on gypsum and methods used for laying

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102013005371.4A DE102013005371A1 (en) 2013-03-28 2013-03-28 Perforated plate based on gypsum and method for laying the same
PCT/EP2014/056199 WO2014154823A1 (en) 2013-03-28 2014-03-27 Perforated boards based on gypsum and methods used for laying

Publications (2)

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EP2978908A1 true EP2978908A1 (en) 2016-02-03
EP2978908B1 EP2978908B1 (en) 2018-07-18

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EP (1) EP2978908B1 (en)
BR (1) BR112015024533B1 (en)
DE (1) DE102013005371A1 (en)
DK (1) DK2978908T3 (en)
ES (1) ES2690585T3 (en)
PL (1) PL2978908T3 (en)
WO (1) WO2014154823A1 (en)

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Also Published As

Publication number Publication date
WO2014154823A1 (en) 2014-10-02
PL2978908T3 (en) 2019-01-31
BR112015024533B1 (en) 2021-12-14
BR112015024533A2 (en) 2017-07-18
ES2690585T3 (en) 2018-11-21
DE102013005371A1 (en) 2014-10-02
EP2978908B1 (en) 2018-07-18
DK2978908T3 (en) 2018-10-29

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