EP3006643B1 - Façade construction and manufacturing method therefor - Google Patents

Description

The present invention relates to a facade construction comprising a load-bearing base, an insulating layer of dimensionally stable insulating boards with a flat and load-bearing outer surface attached to the load-bearing base and a plate covering forming the outer skin of the façade construction of a large number of tile elements made of ceramic or natural stone, which directly by means of an adhesive attached to the insulating layer.

Furthermore, the present invention relates to a method for producing such a facade construction. Facade structures of the type mentioned are known in the art in a variety of configurations. For the preparation of the thermal insulation insulating layer cuboid insulation boards are glued with flat and stable outer surface by means of mortar or full surface using a tile adhesive to a stable surface, such as the outer wall of a building. Subsequently, the plate covering is mounted on the outside of the insulating layer, which provides the rain protection, protects against other effects from the atmosphere and against mechanical stress and the outer design is used.

When installing the tile covering, according to a first variant, a reinforced, flush-mounted plaster is first applied to the insulating layer, which normally has a total thickness between 25 and 35 mm. On the flush can then be glued the plate elements using a cementitious tile adhesive. Alternatively, a decoupling mat using cementitious tile adhesive is first attached to the flush, which can be additionally secured with dowels, after which the plate elements are glued to the decoupling mat. The decoupling mat serves to prevent transmission of voltages from the flush to the plate elements or from the plate elements to the flush. A disadvantage of this variant on the one hand is that the application of the reinforced concealed plaster is time-consuming and costly. Furthermore, it can cause efflorescence of plastics and calcium carbonate from the tile adhesive, resulting in optically disturbing deposits. In addition, according to DIN 18515-1, which applies to encapsulated tiles or slabs with an area ≤ 0.12 m ² , a side length ≤ 0.40 m and a thickness ≤ 0.015 m, which leads to plate elements with format sizes of more than 30 x 40 cm are at least nominally not allowed.

In an alternative variant, the plate covering is mounted using metal support systems which are dowelled to the load-bearing surface of the facade structure, the individual plate elements being fixed to the support system by means of special anchors. An advantage of such support systems is that they are mounted at a predetermined distance from the insulating layer, so that the plate covering is ventilated. A disadvantage, however, is that the thickness of the Plate elements must be relatively large, if the anchor should engage in slots or holes, which are introduced in the side edges or at the back of the plate elements, see for example the publication DE 40 04 103 A1 , For thinner plate elements retaining clips are usually used, however, which overlap on the externally visible surface of the plate elements, whereby the appearance of the facade construction is impaired. Another disadvantage is that the existing between adjacent plate elements joints remain open in such support systems, so that, for example, rainwater can get behind the plate covering. Also, open joints are not always desirable in terms of visual appearance. In addition, the insulating layer is interrupted by the anchorages of the supporting structures on the load-bearing surface of the facade construction, resulting in undesirable thermal bridges. Not least, such support systems are very expensive.

Other constructions are in the publications DE 17 09 311 A1 . EP 2 436 851 A2 . EP 1 489 241 A1 . DE 20 2009 000 717 U1 . DE 103 22 433 A1 EP2726680 B1 US 2014/0202099 described.

Based on this prior art, it is an object of the present invention to provide a facade structure of the type mentioned above with an alternative structure.

To solve the present invention provides a facade structure of the type mentioned, wherein the adhesive is elastically formed and is applied dot-like or caterpillar-shaped on the plate elements and / or on the insulating layer, and that spacers are provided between the plate elements and the insulating layer, which define fluidically interconnected cavities between the individual plate elements and the insulating layer. A significant advantage of the facade construction according to the invention is that the plate elements are attached directly to the insulating layer without the use of an additional support system, which can be dispensed with an armored concealed, resulting in a very simple and inexpensive construction. Furthermore, a decoupling between the insulating layer and the plate elements is effected by the flexible adhesive. Thanks to the use of spacers, a good ventilation of the plate covering is also achieved.

According to one embodiment of the present invention, the insulation boards are provided on their front and / or on their back with a fabric or nonwoven coating. Such a fabric or non-woven is to the effect of advantage that an adhesive or mortar with which the insulation boards are attached to the load-bearing surface of the facade construction, can very well dig into this, whereby a very stable attachment of the insulation boards can be achieved.

Preferably, a stiffening and / or sealing layer, which comprises a paper layer and / or a plastic layer, is arranged directly beneath each woven or nonwoven coating and / or may have a metallic layer, such as an aluminum foil. Such a stiffening and / or sealing layer counteracts distortion of the insulation boards and / or penetration of moisture or steam.

Advantageously, existing joints between adjacent insulation boards are watertight sealed. For example, spreadable and / or fillable sealants in which a fleece or fabric is embedded are suitable for a watertight seal. Also sealing tapes with double-sided fleece lamination can be used for sealing. Overall, a completely waterproof insulating layer is achieved in this way.

The plate elements are preferably made of ceramic, natural stone, metal, glass or plastic.

The panel elements according to an embodiment of the present invention have external dimensions of at least 40 x 40 cm, resulting in a very attractive visual appearance of the facade construction.

The elastic adhesive with which the plate elements are attached to the insulating layer, is advantageously a cement-free adhesive, whereby the efflorescence mentioned above are prevented. In particular, the adhesive is a silane-modified polymer-based adhesive. Such an adhesive is particularly suitable for processing large-sized tiles with external dimensions of at least 40 x 40 cm.

According to one embodiment of the present invention, the spacers are formed by strip-shaped mats or plates which extend below the edge regions of adjacently arranged plate elements and along the joints between these plate elements and are fastened to the insulating layer, the joints being filled with filler material. In other words, spacers formed and arranged in this way not only serve to place the plate elements at a predetermined distance from the insulating layer, but they also serve as a base for grouting the plate elements and limit the amount of filler material needed to fill the joints. Filling the joints with grout prevents rainwater from entering the facade structure in large quantities. In addition, thanks to the filled joints, a visually appealing appearance is achieved.

Preferably, the strip-shaped mats or plates each have a family of fluid channels extending in at least one direction, which fluidly connect the cavities between the plate elements and the insulating layer. In this way, a good ventilation of the facade construction is ensured. In particular, two sets of intersecting fluid channels are advantageously provided, whereby errors in the assembly of the spacers are reliably prevented.

Advantageously, the strip-shaped mats or plates are provided in the region below the joints on their upper side with recesses for receiving the Fugmaterials. Such depressions contribute to the fixation of the Fugmaterials.

Preferably, the strip-shaped mats or plates are provided at least on their underside with a fabric or a fleece in which an adhesive can cling, with which the strip-shaped mats or plates are attached to the insulating layer. In addition, the fabric or the fleece prevents filling of the fluid channels with adhesive. The fabric or nonwoven fabric can be anchored to the underside of the strip-shaped mats or panels by means of a suitable adhesive. Alternatively, it can also be laminated or fused during the manufacturing process of the strip-shaped mats or plates with their material.

Preferably, the strip-shaped mats or plates have a width in the range of 3 to 10 cm. Such a width combines proper operation with low cost.

To achieve the object mentioned above, the present invention further provides a method for producing a facade structure of the type defined above, comprising the steps of: a) attaching dimensionally stable insulation boards with a flat and stable outer surface to a load-bearing surface of a facade; b) attaching spacers of the same height to the insulation boards in such a way, that the spacers protrude outward from the insulation boards; c) punctiform and / or caterpillar-shaped application of an elastic adhesive to the insulation boards and / or the plate elements in areas where no spacers are arranged in the intended mounted state of the plate elements, wherein the amount of adhesive application is greater than the height of the spacers; and d) bonding the plate elements to the insulation boards by pressing the board elements against the spacers, wherein cavities remain between the board elements and the insulation boards due to the dot-shaped and / or caterpillar-shaped application of adhesive in step c).

The insulation boards are preferably fixed in step a) using a mortar, a thin-bed mortar or an adhesive, in particular a silane-modified polymer-based adhesive to the supporting substrate, wherein the mortar, the thin-bed mortar or adhesive punctiform, strip-shaped or full surface on the insulation boards and / or the load-bearing surface can be applied.

The insulation boards may alternatively or additionally be fastened with dowels to the supporting ground.

According to one embodiment of the present invention, after the implementation of step a) between the insulating panels remaining joints on the front of the insulation panels are sealed watertight, in particular using spreadable or spatulable sealants in the preferred nonwoven or fabric or both sides with a Fleece lamination provided sealing tapes are embedded.

The spacers are advantageously attached by means of adhesive to the insulation boards, resulting in a simple fixation.

After performing step d), remaining joints between the plate elements are advantageously filled with filler material, resulting in a closed facade construction to the outside.

• Figur 1 eine schematische perspektivische Ansicht eines Aufbaus einer Fassadenkonstruktion gemäß einer Ausführungsform der vorliegenden Erfindung;
• Figur 2 eine schematische Querschnittansicht des in Figur 1 dargestellten Aufbaus; und
• Figur 3 eine vergrößerte Ansicht des in Figur 2 mit dem Bezugszeichen III gekennzeichneten Ausschnitts.

Further features and advantages of the present invention will become apparent from the following description of a facade structure according to an embodiment of the present invention with reference to the accompanying drawings. That's it

• FIG. 1 a schematic perspective view of a structure of a facade construction according to an embodiment of the present invention;
• FIG. 2 a schematic cross-sectional view of in FIG. 1 illustrated construction; and
• FIG. 3 an enlarged view of the in FIG. 2 Section marked with the reference numeral III.

The FIGS. 1 to 3 show a structure of a facade structure 1 according to an embodiment of the present invention.

The facade construction 1 comprises a supporting base 2, which in the present case consists of masonry. Alternatively, the substrate 2 but also concrete, metal, wood or the like. The supporting ground 2 is normally arranged vertically, even if it is in FIG. 1 is shown in a horizontal position.

Furthermore, the facade construction 1 comprises an insulating layer 3 fixed on the supporting substrate 2, which consists of a multiplicity of dimensionally stable insulation boards 4 with a flat and load-bearing outer surface 5. The insulating panels 4, which are made for example of mineral fibers, polystyrene foam or other suitable insulating material, have on its front side, which forms the outer surface 5, as well as on its opposite back a fleece coating 6. The opposing nonwoven coatings 6 serve as a primer for an adhesive or mortar. Instead of the nonwoven coatings 6 fabric coatings may alternatively be provided. Furthermore, below each nonwoven coating 6, although not shown here, a stiffening and / or sealing layer may be arranged, which may have a paper layer and / or a plastic layer and / or a metallic layer, such as an aluminum foil. Such a stiffening and / or sealing layer counteracts distortion of the insulating panels 4 and / or penetration of moisture or steam. The insulation boards 4 are each fastened to the load-bearing base 2 using a mortar, the mortar in the form of mortar lumps 7 being applied substantially evenly distributed on the back side of the insulation boards 4. In principle, a full-surface bonding by means of tile adhesive or the like can take place instead of the mortar. For smooth surfaces, As for example metal or wood, a polymer-based silane-modified adhesive is preferably used for fastening the insulating panels 4, which is applied to the insulating panels 4 or to the supporting substrate 2 in the form of adhesive beads or adhesive dots spaced apart from one another. In addition, the insulation panels 4 are secured by means of dowels 8 on the supporting substrate 2. The remaining at the front joints 9 between the insulation boards 4 are sealed waterproof using a seal 10, wherein the seal 10 is formed by a spreadable or spatulable sealant, in which a nonwoven or fabric strip or a double-sided provided with a fleece lamination sealing tape is embedded. The seal 10 may in principle but also have a different structure.

The facade structure 1 further comprises a plate covering 11, which has a plurality of plate elements 12 and forms the outer skin of the facade construction. In the present case, the plate elements 12 are large-sized ceramic plates with external dimensions of 50 × 50 cm or more and a thickness in the range of 0.5-2.0 cm. Alternatively, however, it is also possible to use plate elements in the form of natural stone plates, metal plates, glass plates or plastic plates. In addition, the plate elements 12 may in principle have other dimensions. The plate elements 12 are attached to the insulating layer 3 with an elastic adhesive 13, which in the present case is a cement-free adhesive, more precisely a silane-modified polymer-based adhesive, wherein the elastic adhesive 13 in each case in the form of a plurality of beads on the backs of the Plate elements 12 is applied. Alternatively, in principle, a punctiform application of adhesive is possible.

Between the plate elements 12 and the insulating layer 3 extend spacers 14, which are presently formed by adhered to the insulating layer 3 strip-shaped mats or plates with a width in the range of 3 to 10 cm and each below the edge regions adjacent arranged plate elements 12 and along the Joints 15 extend between these plate elements 12. The strip-shaped mats or plates each have two sets of intersecting fluid channels 16. More specifically, these mats or plates consist of a plastic film with square, rectangular or rounded recesses 17 extending from the front, which are arranged in a regular distribution and define the fluid channels 16 between them. The back of the strip-shaped mats or panels is laminated with a non-woven 18, which serves as a primer for a mortar or adhesive and prevents backfilling of the fluid channels 16. Instead of the nonwoven fabric 18 but also a tissue may be provided. The spacers 14 hold the resting on these plate elements 12 at a defined distance from the insulating layer 3. The fluid channels 16 of the spacers 14 ensure that the remaining between the plate members 12 and the insulating layer 3 cavities are fluidly interconnected. The joints 15 between the plate elements 12 are filled with Fugmaterial 19.

For mounting the facade structure 1, the dimensionally stable insulation boards 4 are attached to the supporting surface 2 of the facade structure 1 in a first step. For this purpose, in a first step, the mortar 7 applied to the backs of the insulation boards 4, whereupon the insulation boards 4 are pressed manually on the supporting surface 2. In a second step, the insulation boards 4 are additionally secured by the plate dowel 8 on the supporting substrate 2.

Subsequently, the remaining between the insulation panels 4 joints are sealed watertight at the front of the insulation panels 4. For this purpose, a first layer of a spreadable or fillable sealant is applied to the butt joints 9. Then a sealing tape provided on both sides with a fleece lamination is placed on the applied sealant. Subsequently, a second layer of the coatable or fillable sealant is applied to the sealing tape. In this way, the insulating layer 3 is sealed watertight.

Now, the spacers 14 are glued substantially lattice-shaped along the later existing between the plate elements joints 15 using a suitable adhesive to the insulating layer 3.

In a further step, the elastic adhesive 13 is applied in the form of a caterpillar to the rear sides of the plate elements 12 and / or to the insulating layer 3 in areas in which no spacers 14 are arranged in the completely assembled state of the plate elements 12. The amount of adhesive application is greater than the height of the spacers 14 chosen here. Preferably, the height of the adhesive application is at least about twice as large as the height of the spacers 14.

Subsequently, the plate members 12 are bonded to the insulation panels 4 of the insulating layer 3 by the plate elements 12 are pressed against the spacers 14 until they rest on this. Due to the caterpillar-shaped application of adhesive, cavities remain between the plate elements 12 and the insulating layer 3, which are fluidly connected to one another via the fluid channels 16 of the spacers 14.

In a final step, the joints 15 present between the plate elements 12 are filled with filling material 19. The Fugmaterial 19 also fills the recesses 17 of the spacers 14, whereby a secure hold of the Fugmaterials 19 is achieved. At regular intervals, the joints 15 can also be formed as expansion joints. For this purpose elastic Fugmaterial can be used. Alternatively, commercially available expansion joint profiles can be used.

The facade structure 1 described above has an easy to manufacture and inexpensive construction. In addition, the facade structure 1 thanks to the fluid channels 16 of the spacers 14 fluidly interconnected cavities that set between the plate elements 12 and the insulating layer 3, well ventilated. In addition, water penetrating via the cavities into the facade structure 1 can be removed without any problems through the cavities and through the fluid channels 16 formed in the spacers 14 via the watertight insulating layer 3. The existing between the plate members 12 joints 15 are filled with Fugmaterial 19, resulting in a visually appealing appearance sets. The attachment of the plate elements 12 using a caterpillar-applied elastic adhesive is on the one hand to the advantage that the plate elements 12 of the Insulating layer 3 are voltage-decoupled. On the other hand, thanks to the use of a cement-free adhesive, no efflorescence can occur. In addition, the elastic adhesive is also suitable for fastening large-sized plate elements 12, ie plate elements with external dimensions of 50 x 50 cm and more. Accordingly, the facade construction 1 can be made very flexible.

LIST OF REFERENCE NUMBERS

1

facade construction

2

Carrying underground

3

damp course

4

Insulation Board

5

outer surface

6

fleece coating

7

dabs of mortar

8th

plate anchors

9

butt joint

10

seal

11

paving

12

panel member

13

Elastic adhesive

14

spacer

15

Gap

16

fluid channel

17

deepening

18

fleece

19

grout

Claims (14)

1. A façade construction (1) comprising a load-bearing base (2), an insulating layer (3) fastened to the load-bearing base (2) and that is made of dimensionally stable insulating boards (4) with a level and load-bearing outer surface (4), and a tile covering (11) comprised of a plurality of tile elements (12) produced from ceramic or natural stone forming the outer skin of the façade construction (1) and which are fastened directly to the insulating layer (3) by means of an adhesive (13), the adhesive (13) being formed elastically and being applied to the tile elements (12) and/or to the insulating layer (3) in the form of dots or beads, and spacers (14) being provided between the tile elements (12) and the insulating layer (3) which define cavities connected to one another fluidically between the individual tile elements (12) and the insulating layer (3).
2. The façade construction (1) according to Claim 1, characterised in that the insulating boards (4) are provided on their front side and/or on their rear side with a fabric or fleece coating (6), a reinforcing and/or sealing layer preferably being disposed directly beneath each fabric or fleece coating (6).
3. The façade construction (1) according to any of the preceding claims, characterised in that any butt joints (9) between adjacent insulating boards (4) are sealed water-tightly.
4. The façade construction (1) according to any of the preceding claims, characterised in that the tile elements (12) have external dimensions of at least 40 x 40 cm.
5. The façade construction (1) according to any of the preceding claims, characterised in that the elastic adhesive (13) by means of which the tile elements (12) are fastened to the insulating layer (3) is a cement-free adhesive, in particular a silane-modified, polymer-based adhesive.
6. The façade construction (1) according to any of the preceding claims, characterised in that the spacers (14) are formed by strip-shaped mats or boards which extend below the edge regions of tile elements (12) arranged adjacently to one another and along the joints (15) between these tile elements (12) and are fastened to the insulating layer (3), and that the joints (15) are filled with grouting material (19), the strip-shaped mats or boards preferably each having a multitude of fluid channels (16) extending in at least one direction and which connect cavities provided between the tile elements (12) and the insulating layer (3) fluidically to one another, in particular two multitudes of intersecting fluid channels (16) being provided.
7. The façade construction (1) according to Claim 6, characterised in that the strip-shaped mats or boards are provided on their upper side with indentations (17) for receiving the grouting material (19) in the region beneath the joints (15), and/or that the strip-shaped mats or boards are provided at least on their lower side with a fabric or a fleece (18).
8. The façade construction (1) according to Claim 6 or 7, characterised in that the strip-shaped mats or boards have a width in the region of 3 to 10 cm.
9. A method for the production of a façade construction (1) according to any of the preceding claims which has the steps:

   a) fastening dimensionally stable insulating boards (4) with a level and load-bearing outer surface (5) to a load-bearing base (2) of a façade ;

   b) fastening spacers (14) of equal height to the insulating boards (4) such that the spacers (14) project outwards from the insulating boards (4);

   c) dot- and/or bead-shaped application of an elastic adhesive (13) to the insulating boards (4) and/or the tile elements (12) in regions in which there are no spacers (14) in the correctly fitted state of the tile elements (12), the height of the adhesive application being greater than the height of the spacers (14); d) adhering the tile elements (12) to the insulating boards (4) by the tile elements (12) being pressed onto the spacers (14), cavities remaining between the tile elements (12) and the insulating plates (4) due to the dot- and/or bead-shaped application of adhesive in step c).
10. The method according to Claim 9, characterised in that in step a) the insulating boards (4) are fastened to the load-bearing base (2) using a mortar, a thin-bed mortar or an adhesive, in particular a silane-modified, polymer-based adhesive, the mortar, the thin-bed mortar or the adhesive preferably being applied in the form of dots or stripes to the insulating boards (4) and/or to the load-bearing base (2).
11. The method according to Claim 9 or 10, characterised in that the insulating boards (4) are fastened with dowels (8) to the load-bearing base (2).
12. The method according to any of Claims 9 to 11, characterised in that after performing step a) any butt joints (9) remaining between the insulating boards (4) on the front side of the insulating boards (4) are sealed water-tightly, in particular using sealing materials which can be painted on or be applied with a spatula and into which preferably fleece or fabric or sealing strips provided on both sides with a fleece lamination are embedded.
13. The method according to any of Claims 9 to 12, characterised in that the spacers (14) are fastened to the insulating boards (4) by means of adhesive.
14. The method according to any of Claims 9 to 13, characterised in that after performing step d) any joints (15) remaining between the tile elements (12) are filled with grouting material (19).

Images