EP4047152B1 - Bauplatte und entsprechendes verfahren zur herstellung einer bauplatte - Google Patents
Bauplatte und entsprechendes verfahren zur herstellung einer bauplatte Download PDFInfo
- Publication number
- EP4047152B1 EP4047152B1 EP21158221.8A EP21158221A EP4047152B1 EP 4047152 B1 EP4047152 B1 EP 4047152B1 EP 21158221 A EP21158221 A EP 21158221A EP 4047152 B1 EP4047152 B1 EP 4047152B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- building panel
- reinforcing
- foam board
- reinforcing concrete
- foam
- 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.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 5
- 238000000034 method Methods 0.000 title description 4
- 230000003014 reinforcing effect Effects 0.000 claims description 53
- 239000004567 concrete Substances 0.000 claims description 42
- 239000006260 foam Substances 0.000 claims description 40
- 239000004570 mortar (masonry) Substances 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 9
- 239000004568 cement Substances 0.000 claims description 6
- 239000000654 additive Substances 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 239000004593 Epoxy Substances 0.000 claims description 4
- 230000000996 additive effect Effects 0.000 claims description 4
- 239000011230 binding agent Substances 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 4
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 3
- 239000004795 extruded polystyrene foam Substances 0.000 claims description 3
- 229910052602 gypsum Inorganic materials 0.000 claims description 3
- 239000010440 gypsum Substances 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 2
- 230000001070 adhesive effect Effects 0.000 claims description 2
- 238000011049 filling Methods 0.000 claims description 2
- 239000011490 mineral wool Substances 0.000 claims description 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 2
- 238000005728 strengthening Methods 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 description 4
- 230000002787 reinforcement Effects 0.000 description 3
- 239000004744 fabric Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920006327 polystyrene foam Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000012615 aggregate Substances 0.000 description 1
- 229910052925 anhydrite Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 1
- 239000011083 cement mortar Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000002984 plastic foam Substances 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
Images
Classifications
-
- 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
- E04C2/10—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- 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
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
Definitions
- the invention relates to a building panel comprising a foam board having a front side and a rear side opposite to the front side.
- the core consists of a foamed plastic, such as polystyrene or polyurethane foam.
- a foamed plastic such as polystyrene or polyurethane foam.
- rigid thin facers may be based on cement or polymer with embedded reinforcing fabrics.
- DE3423006C2 , DE4234269C1 , DE102011013739 and EP2758610B1 describe building panels with facers composed of thin bed mortars comprising embedded glass fiber mesh or fabric reinforcement.
- WO0238879A1 discloses a panel with the features of the preamble of claim 1.
- the coefficient of linear thermal expansion of polystyrene foam is about 6 times higher than the coefficient of linear thermal expansion of a facing based on cement mortar.
- the invention solves the problem described above with respect to a building panel by at least one reinforcing concrete bar that is embedded into the foam board, in particular at the front side or rear side of the foam board characterized in that the at least one reinforcing concrete bar comprises reinforcing fibres (claim 1).
- the invention is based upon the finding that said panel provides an improved rigidity and bending strength, prevents the foam board from excessive expansion or contraction, and thus minimizes the risk of warping and bowing when the panel is exposed to changing weathering conditions.
- the building panel according to the invention is suitable for use in many building applications, for instance fertile backers.
- the front side and/or the rear side are flat surfaces.
- the reinforcing concrete bar is a high strength reinforcing concrete bar.
- a multitude of reinforcing concrete bars is embedded inside the foam board at said front side and/or rear side of the panel. This further increases the rigidity of the panel.
- the reinforcing concrete bars are arranged in parallel to one another or form a grid with one another.
- the grid comprises a further reinforcing concrete bar surrounding said grid, in particular in the form of a rectangle surrounding said grid.
- the reinforcing concrete bar has the form of a circular ring and/or a rectangle.
- the foam board is made of or comprises at least one of the following materials: XPS foam, EPS foam, PU foam, PVC foam, phenolic foam or mineral wool.
- the foam board comprises a thickness of 10 mm - 100 mm, in particular 20 mm - 50 mm. These materials and dimensions have been found to be beneficial for the intended application.
- the reinforcing concrete bars comprise at least one of the following: hydraulic binder, in particular cement or gypsum, aggregate, in particular well-graded aggregate, additive, in particular property-improving additive, reinforcing wires.
- the reinforcing concrete bars comprise a polymeric mortar, wherein the polymeric mortar comprises or is made of at least one of the flowing: epoxy, in particular solvent free epoxy, polyurethane, polyester.
- the reinforcing concrete bars have a cross-sectional shape selected from the list: rectangular, polygonal, trapezoidal, triangular or circular.
- the reinforcing concrete bars comprise a cross-sectional width of 4 mm - 40 mm, in particular 5 mm - 20 mm, and/or a cross-sectional depth of 6 mm - 50 mm, in particular 10 mm - 30 mm.
- the volume of the reinforcing concrete bars ranges between 1 % and 10 %, in particular between 2 % and 5 %, of the volume of the foam board.
- the reinforcing concrete bars are spaced from one another perpendicular to a longitudinal axis of the reinforcing concrete bars by 20 mm - 500 mm, in particular by 50 mm - 300 mm. This has been found to be beneficial to provide an optimal weight/rigidity ratio of the panel.
- the building panel comprises at least one facing layer for protecting and strengthening the building panel, wherein the facing layer is arranged at the front side and/or the rear side of the foam board.
- the facing layer comprises or is made of at least one of the following: cement, polymeric material, fleece.
- the facing layer protects the foam from environmental conditions, such as humidity or mechanical impacts. In this way, the usability of the panel is improved for applications like trafficked roofs, terraces and similar, when higher surface resistance to high pressure, abrasion and point loading are necessary.
- the invention relates to a method of manufacturing a building panel in accordance with claim 14.
- the method comprises: shaping a foam board comprising a front surface and a rear surface, forming at least one groove at the at least one surface of the foam board, in particular by cutting or molding, filling the at least one groove with concrete and/or mortar mix, and curing the concrete and/or mortar mix inside the grooves.
- the invention relates to a further method of manufacturing a building panel in accordance with claim 15.
- the method comprises: shaping a foam board comprising a front surface and a rear surface, forming at least one groove at the at least one surface of the foam board, in particular by cutting or molding, inserting at least one reinforcing concrete bar into said groove, securing the reinforcing concrete bar to said groove, in particular by utilizing adhesive.
- Figs. 1 (a)-(g) show building panels 1 in a cross-sectional view.
- the building panels 1 comprise reinforcement concrete bars 3.
- the reinforcement concrete bars 3 are formed in different shapes and sizes as for example, square, triangle trapezoidal or circular, embedded inside at least one side of the foam board 2.
- the reinforcing bars 3 are made of a binder, well graded fillers and may include properties improving additives and reinforcing fibres or wires to achieve rigid, high strength, low shrink, water proof concretes.
- the binder can be hydraulic, as for example, but not limited to: cement, gypsum or anhydrite or polymeric, as for example, but not limited to: epoxy, polyurethane or polyester.
- the cross-sectional width w of the reinforcing bars 3 is selected preferably between 4 mm and 20 mm, and more preferably between 6 mm and 12 mm.
- the depth d of the reinforcing bars 3 is selected preferably between 4 mm and 50 mm, and more preferably between 10 mm and 30 mm, depending on the thickness of the foam board 2 and required panel strengths.
- the spacings X/Y between the reinforcing bars 3 lines longitudinally and transversally are selected preferably from between 20 mm and 500 mm and more preferably between 50 mm and 300 mm, depending on the desired panel strengths. The smaller the spacings, the more rigid and stronger the panel 1, while the smaller the spacings, the higher the weight and cost of the panel 1.
- FIGs. 2(a) - 2(e) some selected designs of reinforcing bars 3 configurations are shown.
- the reinforcing bars 3 form a grid.
- the grid of Fig. 2(b) comprises a further reinforcing concrete bar 3 surrounding said grid in the form of a surrounding rectangle.
- the reinforcing concrete bar 3 of Fig. 2(d) has the form of a rectangle, the reinforcing concrete bar 3 of Fig. 2(e) the forms of a rectangle.
- Figs. 3(a) - 3(d) illustrate a building panel 1 according to the present invention used as core element coated at least from one side with hydraulic, polymeric or plastic facing 4 selected from state of the art.
- the thickness of the facing 4 is preferably between 0,5 mm and 20 mm, more preferably between 1 mm and 10 mm.
- Figs. 4 and 5 illustrate a building panel 1 in cross-sectional and plan views respectively.
- the panel 1 is in planar cuboid form having dimensions of 600x1200x30 mm (width A, length B and thickness t), and are made of standard XPS foam material of a density of 35 kg/m 3 .
- the reinforcing bars 3 are made of polymer modified cementitious mortar having a compressive strength of 300 kg/cm 2 and tensile strength of 40 kg/cm 2 .
- the panel 1 is reinforced on one side with 1 mm polymeric cementitious layer 4 reinforced with fiber-glass mesh embedded in that facing layer 4 as shown in Fig. 4 .
- the building panel 1 according to the state of the art of Fig. 6 have shown a convex bent at the middle of the facer side of about 4 mm, while the building panel 1 according to present invention as described above did not show practically any noticeable bent.
- the volume ratio of the reinforcing bars 3 embedded inside the foam board 2 is about 4 %, that results in decrease of the thermal resistance of the foam board 2 by not more than 4 %.
- Fig. 6 represents a cross section of a building panel 1 according to state of the art, having the same dimensions as mentioned in the building panel 1 described in Figs. 4 and 5 , however without reinforcing bars 3.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Laminated Bodies (AREA)
Claims (15)
- Bauplatte (1) mit einer Schaumstoffplatte (2), die eine Vorderseite und eine der Vorderseite gegenüberliegende Rückseite aufweist, wobei mindestens ein Verstärkungsbetonstab (3) im Inneren der Schaumstoffplatte (2), insbesondere an der Vorderseite oder der Rückseite der Schaumstoffplatte (2), eingebettet ist,
dadurch gekennzeichnet, dass der mindestens eine Verstärkungsbetonstab (3) Verstärkungsfasern aufweist. - Bauplatte (1) nach Anspruch 1, dadurch gekennzeichnet, dass eine Vielzahl von Verstärkungsbetonstäben (3) im Inneren der Schaumstoffplatte (2) an der Vorderseite und/oder der Rückseite der Platte (1) eingebettet sind.
- Bauplatte (1) nach Anspruch 2, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) parallel zueinander angeordnet sind und/oder ein Gitter miteinander bilden.
- Bauplatte (1) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Schaumstoffplatte (2) aus mindestens einem der folgenden Materialien besteht oder dieses umfasst: XPS-Schaum, EPS-Schaum, PU-Schaum, PVC-Schaum, Phenolschaum oder Mineralwolle.
- Bauplatte (1) nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass die Schaumstoffplatte eine Dicke (t) von 10 mm - 100 mm, insbesondere 20 mm - 50 mm, aufweist.
- Bauplatte (1) nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) mindestens eines der Folgenden aufweisen:- hydraulisches Bindemittel, insbesondere Zement oder Gips,- Zuschlagstoff, insbesondere gut abgestufter Zuschlagstoff,- Additiv, insbesondere eigenschaftsverbesserndes Additiv,- Verstärkungsdrähte.
- Bauplatte (1) nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) einen polymeren Mörtel umfassen, wobei der polymere Mörtel mindestens eines der Folgenden umfasst oder daraus hergestellt ist:- Epoxid,- Polyurethan,- Polyester.
- Bauplatte (1) nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) eine Querschnittsform aufweisen, die aus einer Liste ausgewählt ist, die aufweist: Rechteckig, polygonal, trapezförmig, dreieckig oder kreisförmig.
- Bauplatte (1) nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) eine Querschnittsbreite von 4 mm - 40 mm, insbesondere 5 mm - 20 mm, und/oder eine Querschnittstiefe von 6 mm - 50 mm, insbesondere 10 mm - 30 mm, aufweisen.
- Bauplatte (1) nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Volumen der Verstärkungsbetonstäbe (3) zwischen 1 % und 10 %, insbesondere zwischen 2 % und 5 %, des Volumens der Schaumstoffplatte (2) beträgt.
- Bauplatte (1) nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verstärkungsbetonstäbe (3) senkrecht zu einer Längsachse der Verstärkungsbetonstäbe (3) um 20 mm - 500 mm, insbesondere um 50 mm - 300 mm, voneinander beabstandet sind.
- Bauplatte (1) nach einem der vorhergehenden Ansprüche, gekennzeichnet durch mindestens eine Deckschicht (4) zum Schutz und zur Verstärkung der Bauplatte (1), wobei die Deckschicht (4) an der Vorderseite und/oder an der Rückseite der Schaumstoffplatte (2) angeordnet ist.
- Bauplatte (1) nach Anspruch 10, dadurch gekennzeichnet, dass die Deckschicht (4) mindestens eines der Folgenden umfasst oder daraus hergestellt ist:- Zement,- polymeres Material,- Vlies.
- Verfahren zur Herstellung einer Bauplatte (1), insbesondere einer Bauplatte (1) nach einem der Ansprüche 1-13, aufweisend:- Formen einer Schaumstoffplatte (2) mit einer Vorder- und einer Rückseite;- Ausbilden mindestens einer Rille in der mindestens einen Oberfläche der Schaumstoffplatte (2), insbesondere durch Schneiden oder Formen;- Füllen der mindestens einen Rille mit einer Beton- und/oder Mörtelmischung, wobei die Beton- und/oder Mörtelmischung Verstärkungsfasern enthält;- Aushärten der Beton- und/oder der Mörtelmischung in den Rillen.
- Verfahren zur Herstellung einer Bauplatte (1), insbesondere einer Bauplatte (1) nach einem der Ansprüche 1-13, umfassend:- Formen einer Schaumstoffplatte (2) mit einer Vorder- und einer Rückseite;- Ausbilden mindestens einer Rille in der mindestens einen Oberfläche der Schaumstoffplatte (2), insbesondere durch Schneiden oder Formen;- Einsetzen mindestens eines Verstärkungsbetonstabs (3) in die Nut, wobei der mindestens eine Verstärkungsbetonstab (3) Verstärkungsfasern umfasst;- Befestigung des Verstärkungsbetonstabs (3) in der Nut, insbesondere durch Verwendung von Klebstoff.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21158221.8A EP4047152B1 (de) | 2021-02-19 | 2021-02-19 | Bauplatte und entsprechendes verfahren zur herstellung einer bauplatte |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21158221.8A EP4047152B1 (de) | 2021-02-19 | 2021-02-19 | Bauplatte und entsprechendes verfahren zur herstellung einer bauplatte |
Publications (2)
Publication Number | Publication Date |
---|---|
EP4047152A1 EP4047152A1 (de) | 2022-08-24 |
EP4047152B1 true EP4047152B1 (de) | 2023-09-13 |
Family
ID=74797691
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP21158221.8A Active EP4047152B1 (de) | 2021-02-19 | 2021-02-19 | Bauplatte und entsprechendes verfahren zur herstellung einer bauplatte |
Country Status (1)
Country | Link |
---|---|
EP (1) | EP4047152B1 (de) |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2156006A1 (de) * | 1971-11-11 | 1973-07-26 | Fred Konzuch | Betonfachwerk (diagonale anordnung) mit hartschaum- bzw. leichtbauschalelementen, welche gleichzeitig fuell-, putzund isolierteile sind |
DE3423006A1 (de) | 1984-06-22 | 1986-01-02 | Helmut 7583 Ottersweier Meister | Leichtbauteil in form von platten, pflanzkuebeln oder pflanzbehaeltern |
AU586425B2 (en) * | 1985-05-17 | 1989-07-13 | Radva Corporation | Insulating building panel for column and beam structure |
DE4234269C1 (de) | 1992-10-10 | 1994-04-21 | Helmut Wedi | Verfahren zur Herstellung von Verbundplatten |
CN1107775C (zh) * | 2000-11-13 | 2003-05-07 | 张铭 | 外墙外保温装饰成型墙板 |
DE202011001989U1 (de) | 2011-01-27 | 2011-05-12 | Mostafa, Kamal, Dr. | Bauplatte mit einer strukturierten Oberfläche |
DE102011114001A1 (de) | 2011-09-21 | 2013-03-21 | Kamal Mostafa | Bauplatte |
-
2021
- 2021-02-19 EP EP21158221.8A patent/EP4047152B1/de active Active
Also Published As
Publication number | Publication date |
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EP4047152A1 (de) | 2022-08-24 |
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