SI23514A - Building panel as structure of outer and inner plate with intermediate insulating space - Google Patents

Abstract

Building panel is the structure composed of the outer plate (11) and inner (12) plate where between the plates (11) and (12) the intermediate insulating space is incorporated which can include any form of heat and / or sound isolation and preferential does not form solid structure in conjunction with said plates (11) and (12). Plates (11) and (12) are linked together by bond (1). Bond (1) is carried out at least at longitudinal part of the panel. Furthermore, bond (1) consists of sealed polymer profile (2) or composed spacers (7).

Description

CBS INSTITUTE, Comprehensive Building Solutions, d.o.o. FRIENDS ROAD 12 8210 NEEDS

Construction panel as structure of outer and inner panels, with intermediate insulation space

The field of technology

The invention relates to technical solutions for construction with integral thermal and sound insulation, made on the principle of composite, pre-fabricated panel, with a side frame based on polymers and sheet steel, intended for use in building envelopes of integrated and suspended facades.

ECLA proposal: E04C2 / 38E, E04C2 / 38C

A technical problem

With the depletion of the most comfortable fossil fuels to use, our civilization faces the need for new ways of harnessing the remaining energy sources. One way is also to reduce energy consumption for heating, cooling and building construction. Thermal insulation of buildings is important in reducing energy consumption. With the increasing need for efficient thermal insulation, came the need for low thermal conductivity insulation systems. Such systems are based on composite panels that use vacuum panels, nanopowered, aerogels or gas-filled composites as their insulating core. Building panels based on such systems usually cannot utilize their insulation core to provide the load-bearing capacity or rigidity of the panel due to the mechanical weakness of such insulation cores.

The object of the present invention is to propose such a construction of a composite panel, where the outer and inner panels form, through a side bond, a rigid box-like structure of the panel having within it any arbitrary insulating core. The embroidery shall provide rigidity to the panel through mechanical connection of the inner and outer panels and with its own rigidity. However, the embroidery should, as far as possible, effectively inhibit heat transfer and allow the expansion of the panels due to the effect of temperature changes on the building, especially on the outside.

The state of the art

There are three groups of relevant patents in the prior art. The first shows panels with various designs of polymer edges / reinforcements of composite building panels: EP1333129, GB2344834, GB2451275 and W02005070803. Of particular importance is the subset of patents where polymer backbone / reinforcement is combined with internal steel reinforcement: FR2813624, US2004231275 and US4993204. In the second group are patents where the panel is made on the basis of steel reinforcement or spacers: EP1312725, WO9845545. In the third group, there is a patent which deals with the issue of selecting a binder to link elements of the first and second groups: W02004073973.

Patent FR2813624 describes a polymer reinforcement that effectively prevents excess heat transfer and also offers adequate reinforcement in combination with steel reinforcement profiles for panels further mechanically supported by load-bearing insulation cores. For the use of non-carrier insulating cores, as is required in our case, the use of simple thermoplastic extrudates, such as according to patent FR2813624, e.g. PVC, is not sufficient in terms of panel stiffness and does not allow for linear temperature coefficients of elongation. The use of PVC would lead to increased use of internal steel reinforcements, which would, however, impair the highly desirable thermal resistance of this reinforcing bond. Patent EPI333129 proposes the use of glass reinforced pultruded profiles, which are sufficient for use in panels with a support core even without steel internal reinforcements, and in systems without a support core, such a solution would not necessarily be sufficient.

W02004073973 defines an adhesive for bonding side bond elements, namely: the adhesive should be from a group of polyurethanes, epoxies or methacrylates. The adhesive should also have a tensile and / or shear strength of at least 2 MPa. In our study, we proved by experiment that adhesive, which only meets the strength requirement of at least 2 MPa, does not meet the requirements for use on building panels. In our experiment, a polyurethane adhesive with a strength of well over 2 MPa and a modulus of elasticity above 1000 MPa was used for the panel. After installing the test panel in the building, the outer panel, after about two months in the summer, was gone. Hard polymer adhesives with a high modulus of elasticity after exposure to fluctuating daily temperatures between 10 ° C and 75 ° C and above experience a failure of adhesion. This fact has long been known in structural insulation glazing, which also lacks a load-bearing insulation core, where only soft silicone adhesives with a modulus of elasticity of up to 1.5 MPa or a hardness of 20 to 35 Shore A. are used for attaching the outer glass. Insulating glass, the glass itself does not usually provide rigidity of the glass panel, but rather stiffness is provided by large metal elements located mostly entirely on the inside of the building.

Description of the new solution

The technical problem presented above is solved by the building panel as an external and internal panel structure, with an intermediate insulation space. According to the invention, the problem of the building panel is solved by an outer 11 and an inner 12 plate between which there is a solid structural bond 1. The structural bond is at each time fixed with a glue of appropriate thickness and hardness according to an embodiment of the invention. A building panel is a structure of the outer 11 and the inner 12 of the panel, wherein between panels 11 and 12 there is an intermediate insulation space where any form of thermal and / or sound insulation may be used which preferably does not form a solid structure in association with panels 11 and 12. 1 forms a connection between panels 11 and 12. Embroidery 1 is made at least along the elongated portion of the perimeter of the panel. Further, bond 1 comprises a glued polymer profile 2 or a spacer 7.

For better illustration, the invention is provided in two embodiments. The first version of the building panel is the structure of the outer 11 and the inner 12 panels, where the exterior is glass and the interior is plasterboard. Between panels 11 and 12 is an intermediate insulation space, which may be any form of thermal and / or sound insulation, which preferably does not form a solid structure in association with panels 11 and 12, for example vacuum panels, gas-filled panels, melamine foam or nanopen, and aerogels. Embroidery 1 forms a connection between panels 11 and 12. Embroidery 1 is made at least along the elongated portion of the circumference of the panel. Further, the bond 1 comprises from the profile on polymer base 2, into which, alternatively, through the nipples 6 on the polymer profile, an additional profile 3 is firmly attached. At least one thermal insulation pocket 4 is placed in the profile on polymer base 2 at least one adhesive pocket 4. Adhesive 5 based on a rubbery polymer is placed between the polymer-based profile 2 and the plates 11 and 12 and the hardness of this adhesive is between 35 and 70 Shore A. Preferably, the adhesive hardness is between 40 and 50 Shore A. The lower limit of the hardness of 35 Shore A originates from the delimitation with adhesives made of structural glass facades that do not inherently contribute to the rigidity of the glass panels there. In the present invention, the panels 11 and 12 contribute to the stiffness due to the distance between them, and the adhesive should therefore be as rigid as possible. Adhesives with a hardness greater than 70 Shore A for building panel sizes do not provide sufficient mechanical stress compensation due to the temperature expansion of the panel components. According to our research, the most favorable trade-off between higher stiffness and expansion elasticity is an adhesive with a hardness between 40 and 50 Shore A.

The polymer-based profile 2 is made of extruded thermoplastic composite reinforced with 25% to 50% and preferably 40% glass fibers. The polymer-based profile 2 contributes to the flexural rigidity of the panel. Thermoplastic polymers, suitable for use in construction, have relatively small modulus of elasticity ranging from 2000 to 3000 MPa. Thus, a polymer-based profile would make little contribution to the rigidity of the entire panel. In particular, the contribution would be about 10%. It would be economical for the polymer-based profile to also contribute to rigidity. Thermoplastic composites with up to 55% by weight of short or medium fiberglass fill are the prior art. They can be up to five times as rigid as crude thermoplastics. In our study, we found that the preferred choice was a polyamide, polybutylene terephthalate or polyethylene terephthalate thermoplastic with at least 25% by weight of short glass fiber filling. Variants with more than 55% fiberglass, with a profile size of 80 mm or more, are too demanding for the state of the art in extrusion. For the profile size of about 100 mm and the thickness of the walls in the rank of 2 mm, the filling of 40% fiberglass proved to be optimal in terms of the technological process and in terms of product needs. The elastic modulus achieved is 7000 MPa. A thermoplastic composite of less than 25% fiberglass has too large linear temperature extensions in the direction of profile 2 for use in combination with adhesive 5 to our specification. Such a polymer-based profile contributes to a panel rigidity of about 25-30%. The polymer-based profile 2 can also be made by the pultrusion process. The polymer resin here may be based on phenol formaldehyde, unsaturated

pull polyester, vinyl ester or epoxy with glass or basalt fibers and matching fiberglass or basalt fibers through a pultrusion matrix. Fibers may also be a suitable other. A process having substantially less than 50% by weight of fiberglass is not technologically possible here. The glass fiber fill ceiling is technologically conditioned again and is at about 75%. The elastic profile modules available here are much higher and range from 15000 to 25000 MPa. The Pultrusion process is more complex. In this case, the modulus of elasticity of the polymer-based profile are so high that the rigidity achieved is sufficient even without the use of an additional profile 3. The polymer-based profile 2 may also comprise one or more heat-insulated pockets 4 filled with air or thermal insulation material. . In the case of extruded profile 2, these pockets are usually larger and smaller. Therefore, in order to prevent air convection and heat transfer by radiation, it is not usually necessary to fill these insulation pockets with additional insulation. However, in the case of pultruded profile 2, the construction with a plurality of insulation pockets is demanding. In this case, only one larger insulation pocket can be made, which should, however, be filled with thermal insulation, such as. polyurethane foam.

Embroidery 1 further comprises adhesive 5, which is a composite based on a rubbery polymer based on a polyurethane, silicone or preferably polysulfide base. In the composition of composite adhesive 5, conventional or special fillers are also present, such as e.g. calcite and other fillers to achieve the desired characteristics. The adhesive layer 5 must be at least 1 mm thick in order to achieve adequate temperature-dilatation resistance and to ensure fault tolerance in the product tolerances. A thickness greater than 5 mm would already significantly reduce the rigidity of the panel, with best results being obtained for thicknesses between 2 and 3.5 mm.

An additional reinforcement profile 3 may be metal or. steel structural pipe. However, mineral materials can also be used to reduce heat transfer. Maybe it would be also use glued glass beams.

Another embodiment of the building panel is the structure of the outer 11 and inner 12 panels with an intermediate insulating space. Embroidery 1 between panels 11 and 12 is made at least along the elongated portion of the circumference of the panel. Embroidery 1 comprises two or more substantially one along the other loaded spacers 7 which are connected to each other by at least one layer of polymer adhesive 8, hardnesses between 45 and 95 Shore A, preferably between 60 and 85 Shore A.

Spacers 7 may be rectangular metal tubes, with or without ribbing, generally made of thin stainless steel with a thermal conductivity of less than 16 W / mK. As such, commercial steel spacers of the prior art can be used. Spacers can be hybrid designs where the profile is made of partly metal (stainless steel) and partly polymer rectangular tubes, such as hybrid ("warm edge") spacers from the prior art thermal insulating glass.

Spacers 7 can also be made of elastic polymer foam or based on mineral, metal foam or honeycomb.

The best thermal resistance is offered by the hybrid spacer 7 because the thickness of the steel half spacer is between 0.05 mm and 0.20 mm. Thicknesses below 0.05 mm are too thin for the mechanical strength of the spacer, and thicknesses greater than 0.20 mm are conveying too much heat. A thickness of about 0.1 mm is optimal in our study. Due to the special features of the system of the invention, polymers that are less expensive and conduct less heat than those in the state of the art of insulating glass can also be used for the polymer part of the hybrid spacer with a thickness of about 1 mm. These are e.g. polyvinyl chloride (PVC) and polystyrene (PS). Polycarbonate (PC) and polypropylene (PP) are usually used for insulating glass.

Embroidery 1 in addition to spacers in another embodiment also comprises adhesive 8, which is based on metaacrylic or hybrid polyurethane. The applicant did not find any other adhesive with appropriate structural properties along with a suitable cure time. As with the first panel version, the adhesive hardness combined with the thickness is also important here. A minimum of 45 Shore A hardness is required to achieve a stiffness of a stack of more than one spacer. A stiffness of more than 95 Shore A would cause premature shearing of the adhesive joint between the panels 11 and 12 in the corners when external forces applied to the panel (eg wind). Use of adhesive with a final hardness of between 60 and 85 Shore A. is optimum. The adhesive layer should be between 0.1 and 1 mm. There may also be two layers of adhesive between the spacers. Less than 0.2 mm of total adhesive thickness between the adhesive spacers compromises the flexibility of the joint when wind is applied to the panel, and more than 1 mm no longer gives sufficient rigidity. Adhesive thickness between d 0.2 and 0.5 mm is optimal.

Implementation examples

In the first embodiment, the hypothesis was tested that the polymer adhesive meeting the condition of patent application W02004073973 that the adhesive must have a tensile and / or shear strength greater than 2 MPa is sufficient to bond a system similar to the invention. The panel was manufactured in accordance with the first embodiment of the present invention. In the 1.4 m long and 1 m wide panel, we used dark gray enameled float glass from local manufacturer Reflex, 8 mm thick, for the outer panel 11. The inner panel 12 was a 15 mm thick Rigidur H panel manufactured by Rigips. The panel was fitted with polymer profiles 2 along the longer side, as shown in Figure 1. The profile 2 was 100 mm wide and 43 mm thick. It was made of BASF polyamide 6.6 GF40. A standard rectangular steel profile 3 was inserted into profile 2; 50x30x2,5 mm. The adhesive between polymer profile 2 and the panels was polyurethane, 1 part isocyanate and 4 parts polyol. The isocyanate was Suprasec 5025, manufactured by Huntsman, and the polyol by Mitopur Al / 5, a local manufacturer of Mitol. The adhesive had a modulus of elasticity of about 2500 MPa and a tensile strength greater than 2 MPa. 100 mm thick styrofoam was used for the insulating core of the panel. Prior to bonding, polymer profile 2 was prepared to improve adhesion with adhesive. The panels made in this way were installed in the experimental building. After about 60 days of summer weather at latitude about 45 °, the outer panels began to fall off. With this experiment, we proved that the adhesive strength criterion above 2 MPa was not decisive for choosing a suitable adhesive in a system like ours.

For the second embodiment, the panel was made only using another embodiment of our invention. For panel 1 m long and 0.5 m wide, we used enameled float glass of dark gray, from local manufacturer Reflex, 8 mm thick, for exterior panel 11. The inner panel 12 was a 15 mm thick Rigidur H panel manufactured by Rigips. For spacers 7, we used modified Chromatech Ultra spacers with a nominal height of 20 mm from Rolltech. The polymer part of the spacer was made of polystyrene. We stacked 5 rectangular ones, completed across the entire perimeter of the panel)

spacers, which also had aluminum foil insulation core, which was a gas-filled panel. A structural hybrid acrylic polyurethane adhesive, SikaFast 3131, manufactured by Sika, 0.3 mm thick, was used between spacers and also between spacers and plates. The adhesive has a hardness of 80 Shore A. Such a panel has a suitable rigidity of up to 3 m in length for construction up to one storey buildings.

For the third embodiment, we used the two solutions of the invention together. For 10 panels 2.6 m long and 1 m wide, we used a transparent, tempered float glass, from the local manufacturer Reflex, 8 mm thick, for the outer panel 11. The inner panel 12 was a 15 mm thick Rigidur H panel manufactured by Rigips. For spacers 7, we used modified Chromatech Ultra spacers with a nominal height of 20 mm from Rolltech. The polymer part of the spacer was made of polystyrene. We stacked 5 rectangular, completed (along the entire perimeter of the panel) spacers, which also had aluminum foil insulating core, which was a gas-filled panel. A structural hybrid acrylic adhesive, SikaFast 3131, manufactured by Sika, 0.3 mm thick, was used between the spacers. The panel was fitted with polymer profiles 2 along the longer side, as shown in Figure 1. The profile 2 was 100 mm wide and 43 mm thick. It is made of BASF polyamide 6.6 GF40. A standard rectangular steel profile 3 was inserted into profile 2; 50x30x2,5 mm. The adhesive between profile 2 and panels 11 and 12 was GDI 16 polysulphide adhesive manufactured by Komerling chemische fabrik, 38 Shore A hardness and 3.5 mm thick. Prior to bonding, polymer profile 2 was prepared to improve adhesion by adhesive through a plasma treatment process. The panels described in this way have been thoroughly tested for rigidity and strength. The panel was able to withstand wind load up to 35 kN from the point of view of strength. In terms of stiffness, however, at a nominal overhang of the inner panel of 12 L / 200 = 13 mm, the panel withstood a wind load of 12 kN or 4.6 kPa of wind load. This corresponds to a stagnant wind pressure of 85 m / s and 306 km / h, respectively. The panels were additionally exposed to 1000 cycles of such wind load and were also installed in the test facility, where real temperature stress loads were also passed.

For CBS INSTITUljlceloviie Building Solutions, d.o.o.

Dr. Jure Mari, Patent Agent

Claims (15)

PATENT APPLICATIONS E Construction panel as a structure of the outer (11) and inner (12) panels, with an intermediate insulating space, characterized in that the bond (1) between the panels (11) and (12) is made at least along the elongated part of the circumference of the panel, where the bond ( 1) At least a. a polymer-based profile (2), with at least one heat-insulating pocket (4) between the panels (11) and (12) in the polymer-based profile (2), and b. adhesive (5) based on a rubbery polymer, which is at least between the polymer-based profile (2) and the plates (11) and (12), the nominal hardness of this adhesive being between 35 and 70 Shore A, preferably between 40 and 50 Shore A. Building panel according to claim 1, characterized in that the polymer-based profile (2) is made of extruded thermoplastic composite reinforced with 25% to 55% and preferably 40% fiberglass. Building panel according to claim 2, characterized in that the profile on the polymer base (2) is made on the basis of polyamide, polybutylene terephthalate, polyethylene terephthalate or their blend. Building panel according to claim 1, characterized in that the polymer-based profile (2) is made of pultruded duroplastic composite reinforced with 50% to 75% by weight of fibers from glass, basalt, matching braids or a combination thereof. Building panel according to claim 4, characterized in that the polymer-based profile (2) is made on the basis of phenol formaldehyde, polyester, vinyl ester or epoxy with associated fillers. Building panel according to claim 5, characterized in that fillers with a thermal conductivity of less than 0.2 W / mK are added to the profile material on the polymer base (2). Building panel according to claim 1, characterized in that at least one thermal insulation pocket (4) is filled with thermal insulation material. Building panel according to claim 1, characterized in that the adhesive (5) is a composite based on polyurethane, silicone or preferably polysulfide, wherein the thickness of the composite (5) is 1 mm to 5 mm, and preferably 2 mm to 3.5 mm. Building panel according to claim 1, characterized in that an additional profile (3) can be inserted into the profile on the polymer base (2), which can be metal or mineral. 10. Building panel as a structure of outer (11) and inner (12) panels, with an intermediate insulating space, characterized in that the connection (1) between the panels (11), (12) is made at least along the elongated part of the panel circumference, where the bond (1) comprises at least two substantially one substantially along each other loaded spacers (7), interconnected by at least one layer of polymeric adhesive (8), with a hardness between 45 and 95 Shore A, preferably between 60 and 85 Shore A. Building panel according to claim 10, characterized in that the spacers (7) are metal rectangular pipes, partly metal partly polymeric rectangular pipes, profiles of rectangular section made of polymer, mineral or metal foam or. honeycomb. Building panel according to claim 11, characterized in that the spacers (7) are partly metal partly polymeric rectangular pipes, wherein the metal part is made of stainless steel sheet, 0.05 mm to 0.20 mm thick, and preferably about 0 , 1 mm. Building panel according to claim 11, characterized in that the spacers (7) are partly metal parts of a polymer rectangular tube, wherein the polymer part is made of a thermoplastic polymer based on polyvinyl chloride or polystyrene, about 1 mm thick. Building panel according to claim 10, characterized in that the polymer adhesive (8) is based on methacrylate or hybrid polyurethane. Building panel according to claim 10, characterized in that the respective polymer adhesive layer (8) is 0.2 mm to 1 mm thick on average and preferably 0.3 mm to 0.5 mm thick. For CBS INSTITUTE, Comprehensive Building Solutions, d.o.o.