RU2357053C2 - Construction panel with decorative finish - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: construction panel is related to lightweight fencing structures, in particular to three-layer wall panels, and may be used as fencing structure of low-rise residential buildings. Construction panel comprises wooden frame, non-structural heat insulation material, internal sheeting fixed on top of frame bars, and external sheeting. On top of external sheeting decorative finish is installed from stone or ceramics. Distance between internal and external sheetings is less than height of frame bars installed along panel perimetre, by value that is more or equal to half of decorative finish thickness. Frame bars are made of plates, which are laid in several layers and joined by glue layers.

EFFECT: increased resistance to external effects, rigidity, shape stability and strength of three layer wall panel.

6 cl, 9 dwg

Description

The invention relates to building elements, and more specifically to lightweight building envelopes, mainly for residential low-rise buildings, in particular three-layer wall panels with a rigid inner frame, sheet sheathing, insulation made of effective heat-insulating materials and decorative facing made of natural or artificial stones.

Further, the panel sheathing facing the mounted panel inside the building will be referred to as the inner skin for brevity, and the sheathing facing the mounted panel outside the building will be referred to as the outer sheathing.

Known hinged composite panels containing a layer of heat-insulating material, coated on the front side with a thin decorative cladding [US patent No. 4052831 class. E04F 13/08]. The panels are attached to the supporting wall. The disadvantage of panels is that they cannot fulfill the role of a supporting fence, but serve only for insulation and decoration of the structure.

Famous buildings with decorative facing in the form of cladding from natural or artificial stones [see magazine Beautiful Homes No. 6, 2007, 1st page cover, page 10 or US patent No. 5274982 to class. E04F 13/14]. The process of installing such finish on a building is very laborious and therefore unsuitable for mass construction.

Flexible decorative panels are known whose surface imitates natural materials: masonry or brickwork, wood paneling [US Pat. No. 6,237,294 by class. B28B 7/00]. Panels are fixed on the outer surface of the bearing walls of structures with the purpose of decorating them and protecting them from atmospheric influences. The disadvantage of the panels is that they are not load-bearing and insulating.

Known facing plate, which is a pressed plate with a front layer of crushed natural or artificial stones or ceramic particles with a particle size of 1-10 mm, connected to the substrate by means of an adhesive layer [certificate of the Russian Federation for utility model No. 19501 according to class. B44C 5/04]. The disadvantage of the slab is that it cannot serve as the bearing wall of the structure and must be attached to the bearing walls, which increases the complexity of construction. The use of glue for fixing the elements of the front layer limits their size to 1-10 mm, while there is a significant need for larger, thicker and heavier decorative elements, for example, imitating masonry from hewn or untreated natural stones or bricks.

Known three-layer building panel containing a frame of steel profiles, which is part of the inner frame having reinforcement from wooden beams, non-structural insulation and sheet sheathing [RF patent №2245970 class. E04C 2/26]. The panel has high strength and dimensional accuracy provided by the use of a steel frame from an angular rolling profile. But the presence of this frame makes the panel heavier and more expensive, which is its main drawback.

Closest to the proposed technical essence is a three-layer wall panel containing a frame made of wooden beams, to which flat asbestos-cement sheathing sheets are attached on two sides of the screws. Non-structural insulation is placed between the sheathing sheets [Typical structures of buildings and structures. Series 1.832-1. Lightweight wall panels for agricultural production buildings. Issue 1. 3 m long panels on a wooden frame with asbestos-cement sheathing]. The disadvantage of the panel is its low decorativeness and lack of weather protection. Installing decorative finishes on a panel already installed in a building is a very time-consuming and expensive process. The panel does not have high strength and rigidity at sizes over three meters. This forces during the construction of the most popular two-three-story residential buildings now to assemble a wall fencing from several panels, which increases the cost and delays the construction. A large number of joints between small panels reduces the reliability of the building's insulation.

If the massive decorative decoration made of stones is installed on the panel during its manufacture, then, due to insufficient rigidity and strength, the decorative layer or its elements are separated from the asbestos-cement plate, especially when transporting panels, moving them from horizontal to vertical and when mounting them in a building . When slinging such panels in an upright position, they warp towards a heavier stone cladding, which complicates installation.

The technical result achieved by this proposal is to increase the decorativeness and resistance to external influences, rigidity, shape stability and strength of a three-layer wall panel.

This result is achieved by the fact that in a building panel containing a wooden frame, non-structural insulation, an inner sheet sheathing mounted on top of the beams of the skeleton, and an outer sheet sheathing, a decorative finish made of stone or ceramic is installed on top of the sheathing, the distance between the inner and outer sheathing is less than the height frame beams located around the perimeter of the panel, an amount greater than or equal to half the thickness of the decorative finish.

In addition, the frame is made of plates laid in several layers and connected by adhesive layers.

In addition, the plates of each subsequent layer overlap the joints of the plates of the previous layer by at least half its width.

In addition, in the bars of the frame located around the perimeter of the panel, the width of the plates located between the skins exceeds the width of the plates located outside the skins.

In addition, the outer skin is laid between the plates forming the bars located around the perimeter of the panel and connected to them by adhesive layers.

In addition, part of the plates are laid at intervals.

In addition, embedded parts, for example, for connecting the panels to each other, are installed at least in part of the gaps.

Due to the location of the decorative decoration made of stone or ceramic on the surface of the outer skin, the decorativeness of the panel and its resistance to external influences increase, the cost of the exterior decoration of the building is reduced, and the construction time is reduced.

Due to the fact that the distance between the claddings is less than the height of the beams of the frame located around the perimeter of the panel by an amount greater than or equal to half the thickness of the decorative finish, the rigidity and strength of the panel mounted in the building are increased, the reliability of fixing massive decorative elements in the panel is increased, panel installation is facilitated into the building by eliminating its warping when slinging, since the decorative finish is placed in the recess between the bars located around the perimeter, and rests on them when the panel is installed in a vertical position.

Due to the fact that the decorative finish is buried between the beams of the frame located around the perimeter of the panel by an amount at least equal to half the thickness of the finish, in the panel mounted in the building, installed in a vertical position, there are no forces directed outside the building, that is, trying to unscrew panel from the building. This also reduces the forces that warp the panel when it is slinged over the upper edge in a vertical position, which facilitates installation.

Due to the fact that the wooden frame of the panel is made of plates laid in several layers and connected by adhesive layers, the rigidity, strength and shape stability of the panel significantly increase, allowing it to bear a significant load from the massive decorative cladding.

Due to the fact that the plates of each subsequent layer overlap the joints of the plates of the previous layer by at least half their width, the maximum rigidity, strength and shape stability of the panel are achieved, the cost of lumber used for the manufacture of the frame is reduced, due to lower requirements for their quality.

Due to the fact that the width of the plates forming the bars located around the perimeter of the panel located between the skins exceeds the width of the plates located outside the skins, the manufacture of the panel is simplified and cheapened.

Due to the fact that the outer skin is laid between the plates forming the bars located around the perimeter of the panel and connected to them by adhesive layers, the manufacture of the panel is further simplified and its rigidity and strength are increased.

Due to the fact that part of the plates forming the perimeter of the frame is laid at intervals in which embedded parts are installed, the reliability of fixing the panel in the building is increased, its manufacture and installation in the building are simplified.

The essence of the proposal is illustrated by drawings.

Figure 1 shows a view of the proposed panel from the side of the decorative finish.

Figure 2 shows a cross section of the proposed panel with a frame of solid bars.

Figure 3 shows a cross section of a variant of the proposed panel, in which the plates of the bars of the outer perimeter of the frame have a different width.

Figure 4 shows a cross section of an embodiment of the proposed panel, in which the casing facing the outside of the building is laid between the plates forming the bars located around the perimeter of the panel and connected with adhesive layers.

Figure 5-9 shows the manufacturing stage of the proposed panel with a frame of glued plates starting from the first layer of plates (figure 5) to the fifth final layer of the plates (figure 9).

The proposed panel consists of a wooden frame 1. The frame 1 is formed by bars 2 of the outer perimeter and the inner bars of the reinforcement 3. The frame of the proposed panel can be made of solid wood beams or glued wooden beams or glued as a whole of wooden plates 4 (boards). The latter option is the most durable and its use is advisable for large panels with heavy decorative cladding. For cladding of relatively thin ceramic tiles imitating brickwork, the strength and stiffness of the frame of solid bars with a panel length of up to three meters is sufficient.

To the frame from the side, which after installation will be facing the inside of the building, sheet sheathing 5 is attached. Further, this sheathing 5 will be called internal.

Sheet sheathing 6, which after installation of the panel will be facing the outside of the building, is installed inside the frame 1 so that the distance B between it and the sheathing 5 is less than the height H of the bars 2 of the outer perimeter. Further, this skin 6 will be called external. The gap between the skin 5 and 6 is filled with non-structural insulation 7.

Decorative trim 8 is located on top of the outer skin 6 in the recess formed by it and the bars 2 of the outer perimeter protruding above it. Figs. 1-4 show decorative trim 8 as an example. Figs. 1-4 show decorative trim 8 as an example in the form of cladding made of ceramic stones imitating masonry made of hewn wild stone.

Between the thickness of decorative finishes C and the values of B and H, the ratio: H-B≥0.5C. In verbal terms, this means that the decorative finish 8 is recessed in the recess formed by the beams 2 and the sheathing 6, not less than half its thickness.

In the embodiment of the panel shown in FIG. 2, the outer skin 6 is laid on the reinforcement bars 3 and additional plates 9 adjacent to the bars 2 of the outer perimeter and fastened to them.

In the panel embodiment shown in FIG. 3, the outer skin 6 is laid on the bars of the reinforcement 3 and the inwardly protruding part of the plates 4, of which the bars 2 of the outer perimeter are glued. The protrusion of the plates inward is ensured by the fact that those of them that are located between the skin are wider than those that are located above the skin 6.

If the bars 2 are made of solid wood, then a quarter can be selected in them from the side facing the inside of the frame, on the shelf of which the lining 6 is laid.

In the embodiment of the panel shown in FIG. 4, the glued bars of the frame, the outer skin 6 is laid on the bars of the reinforcement 3 and glued between the plates forming the bars 2 of the outer perimeter of the frame.

In the manufacture of the frame 1 glued from the plates 4, they are stacked so that the plates of the subsequent layer overlap the joints of the plates of the previous layer, as shown in FIGS. 5-9, and so that the plates of each subsequent layer overlap the joints of the plates of the previous layer at least half their width. This achieves high strength of the frame with low requirements for the quality of the material of the plates, that is, to the grade of wood used. During gluing the frame in between the plates 4 can be installed embedded parts 10 (Fig.6), which serve to connect the panels to each other and with the floors of the building.

Figure 7 shows a variant of the panel with additional plates 9 and casing 6, fastened to the frame 1 by means of screws 11.

Figure 4 shows a variant of the panel with a casing 6 glued between the plates 4 of the bars 2 of the outer perimeter of the frame.

The proposed panel in the performance with a glued frame of five layers of plates is made as follows.

On the installation table, the inner lining 5 is laid and coated with glue. On it they lay in advance the plates 4 of the first layer cut in predetermined dimensions (FIG. 5). The surface of the plates is smeared with glue and the plates 4 of the second layer are laid on them (Fig.6). In this case, the plates 4 of the second layer are stacked so that they overlap the joints of the plates 4 of the first layer. The amount of overlap (the distance between the joints of adjacent layers of the plates) must be at least half the width of the plate, otherwise the strength of the frame is reduced. If required, then in between the plates of the second (possibly third) layer are installed and fixed embedded parts 10.

The surface of the plates of the second layer is smeared with glue and plates 4 of the third layer are laid on them (Fig. 7). The plates of the third layer should overlap the joints between the plates of the second layer. Further, the manufacturing process can occur in three ways. According to the first embodiment (Fig. 2 and Fig. 7), the gluing of the carcass continues until the last layer, after which inside the carcass additional plates 9 are fastened to the bars 2 forming the outer perimeter, which serve as a support for the outer skin 6. Inside the carcass, non-structural insulation 7 is laid, the outer casing 6 is laid on top of it and secured with screws 11. It is also possible to glue the casing with the frame 1. To tighten the package of plates and fix the plates in the package, they are connected with nails or screws 12. It is possible to press the package, but in practice ka showed that tightening with screws is quite enough to obtain reliable bonding. After the plates are pulled together, excess glue that protrudes outward is removed, and the casing is sent to the dryer.

After drying the frame with the installed casing and insulation in the recess formed by the beams 2 of the outer perimeter and the casing 6, decorative decoration 8 is laid and fixed.

The described option is more time-consuming than subsequent ones, but it is advisable when there is a shortage of lumber of sufficient width. In addition, additional plates 9 strengthen the frame and increase its shape stability in conditions of variable humidity.

According to the second variant (Fig. 3), the plates 4, forming the bars 2 of the outer perimeter, in the first three layers located between the casing, have a width several (3 ... 4 cm) greater than the width of the plates of the fourth and fifth layers located above the outer casing. Due to this, a ledge is formed, on which the outer skin 6 rests. This option is more technologically advanced than the first, but requires the first three layers of wider lumber for the plates, which is not always possible.

According to the third, most technologically advanced variant, the casing 6 is glued between the plates of the third and fourth layers, as shown in Fig. 4. In this case, the plates 4 of all layers have the same width. For a more reliable fastening, the package of plates and casing can be additionally pulled together with studs. Before installing the casing 6, a non-structural insulation 7 is inserted into a partially made frame.

To reduce warpage, it is preferable that in all cases the plates are assembled in a bag with an alternating change in the convexity direction of the original log, as shown in Figs. 3 and 4. The surfaces to be glued on the plates are not planed, the villi and burrs remaining after sawing the logs additionally reinforce the adhesive joint. The reinforcing action of the villi allows local increases in the thickness of the adhesive layer without reducing the strength characteristics of the frame beams. This avoids calibrating the processing of plates on a thicknessing machine, which significantly reduces the cost of production. Cracks, potholes and other violations of the continuity of the plates do not reduce the strength of the frame, since, filling with glue, they even improve the reliability of the adhesive joint. This also reduces the requirements for the quality of the material of the plates, and the frame of the proposed panel can be made of material with a grade one or two units lower than in the closest analogue. A small overview on the edges of the plates facing the inside of the frame is also allowed.

When installing the proposed panel in the building, it is installed in a vertical position. Due to the fact that the decorative finish is buried inside the panel frame, the projection of its center of gravity does not extend beyond the lower panel bar, it rests on the lower panel bar, and therefore there is no moment turning the panel out of the building. Most often, decorative cladding is lined with natural or ceramic stones that have a lot of weight, and in these cases, this advantage is especially important. In addition, installation of the panel is facilitated, since it does not tilt when slinging. Additionally, panels of the outer perimeter of the panel protect the finish from damage during transportation and installation. The joints between such panels are closed with decorative overlays.

Decorative decoration with stones or ceramic tiles performs not only a purely decorative, but also a protective function, preventing the direct impact of the atmosphere on the outer skin and through it on the insulation, protecting the walls of the building from mechanical damage.

The proposed panel along with decorative trim is manufactured at the factory. Despite the laboriousness of assembling the glued carcass, the final laboriousness of the construction is lower, since the carcass is glued in workshop conditions from pre-prepared plates to the size of the panels, the installation of the panels is not complicated by their distortion on slings, it is possible to manufacture rigid panels of large (up to 6 ... 9 meters) length , immediately to the entire height of a multi-story building. If the installation of decorative elements was carried out on an already mounted panel installed in a vertical position and located in the open air, the total labor input would be almost twice as much.

Claims (6)

1. A building panel comprising a wooden frame, non-structural insulation, an inner sheathing reinforced over the beams of the skeleton, and an outer sheathing, characterized in that a decorative finish made of stone or ceramic is installed on top of the sheathing, the distance between the inner and outer sheaths is less than the height of the beams frame located around the perimeter of the panel, an amount greater than or equal to half the thickness of the decorative finish, and the frame bars are made of plates laid in several layers and connected GOVERNMENTAL adhesive layers. 2. The construction panel according to claim 1, characterized in that the plates of each subsequent layer overlap the joints of the plates of the previous layer at least half its width. 3. The construction panel according to claim 1 or 2, characterized in that in the beams of the frame located around the perimeter of the panel, the width of the plates located between the skin exceeds the width of the plates located outside the skin. 4. The construction panel according to claim 1 or 2, characterized in that the outer skin is laid between the plates forming the bars located around the perimeter of the panel and connected to them by adhesive layers. 5. The building panel according to claim 1, characterized in that part of the plates are laid at intervals. 6. The construction panel according to claim 5, characterized in that at least in part of the gaps embedded parts are installed, for example, for connecting the panels to each other.

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