Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/1271—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed parts being partially covered
• • 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
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0801—Separate fastening elements
  • E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
  • E04F13/0833—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
  • E04F13/0835—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining

Definitions

• a fa ⁇ ade element especially a fa ⁇ ade board and the method of manufacturing the fa ⁇ ade element
• the subject of invention is a fa ⁇ ade element, especially a board and the method of manufacturing the fa ⁇ ade element, especially the board.
• Patent application P 334890 provides a description of a building board for building facilities' insulation.
• the board has an arm made of cold bent channel section to which a trapezoid metal sheet is welded from the inside.
• the trapezoid metal sheet is covered with a sheet of foamed insulating material, for example EPS (expanded polystyrene) , to which a metal net is stuck with its external surface covered with a layer of plaster.
• EPS expanded polystyrene
• utility model No. W 61003 reveals a two- layer insulating facade board for insulating the external walls of buildings, which consists of a polystyrene foam board covered with a protective layer of plaster.
• a fa ⁇ ade cladding system which consists of a board and a fastening assembly for supporting these boards, while from the description of patent P-347984 we know an insulating board with a core made of heat-insulating material, whose minimum one surface is covered with a layer of polyurethane.
• the aim of the invention is to form a self-supporting ready-made fagade element which does not require an additional fastening structure and whose insulating layer constituting a heat insulator is made of formed polyurethane. Another goal is to obtain a self-supporting insulating element the insulating layer of which contains a grip supporting structure to mount on the wall and ceiling. Another goal is to provide a fagade which is resistant to environmental effect and has no thermal bridges. Further, the aim of the invention is to ensure a fast and reliable assembly of the fagade element on a wall, which is cheap and reliable with regard to insulating power.
• the fagade element especially the board proposed in the invention, composed of an external layer of lining, joined with a plastic insulating layer and equipped with a mounting assembly is characterized in that the insulating layer has been made from formed polyurethane foam a.nd is integrated with the external layer, and inside the insulating layer there is a mounting assembly in the form of a grip supporting structure, containing minimum one section, preferably a flat bar with transversely joined bars; each section, at least on one of its ends protrudes beyond the outline of the fa ⁇ ade element and has a part bent diagonally towards the bottom of the fa ⁇ ade element and further bent towards its edge, finished with a mounting eye protruding beyond the contour of the fa ⁇ ade element; there are overpresses on the diagonally bent part, while the bent part with a protruding mounting eye is located in the plane of back surface of the insulating layer made from formed polyurethane, while minimum one transverse bar of the grip supporting structure has a shaped spacing protru
• polyurethane foam of the insulating layer should have density of 80 - 100 kg/m3 , and thickness dependent on the size of the expected thermal resistance U.
• the insulating layer protrudes beyond the outline of the element by a distance which provides an expansion gap between external layers of the neighbouring elements.
• Recesses are located in the mounting eye line on the side opposite the mounting eyes .
• the section protrudes beyond the outline of the fa ⁇ ade element from both sides by a distance dependent on the shape of the supporting structure of the fa ⁇ ade element.
• the part of grip supporting structure embedded in the insulating layer is stiff, while its part protruding outside is deformable.
• the section should have eyes on both ends. Sections are connected with transverse bars by means of joints .
• the height of spacing protrusion is suited and proportional to the thickness of insulating layer.
• the sections are placed parallel to one other, in particular the sections should be convergent to each other at an angle ensuring a distance between them along the whole length of the fagade element.
• Mounting eyes are located from the side of the greater distance of sections in relation to each other.
• the grip supporting structure contains one diagonally placed section.
• the fa ⁇ ade element is formed as a supporting board, which constitutes the fa ⁇ ade lining, and the external layer is made of a material selected from the group which includes : natural stone, conglomerate, gypsum, plastic and the like.
• the fagade element is favourably shaped as a reveal, cornice, flagstone and the like.
• the manner of manufacturing the fa ⁇ ade element, especially the board, as proposed in the invention, where the fa ⁇ ade element is formed with a mounting assembly containing an external layer which plays the role of a lining and insulating layer, is characterised by the following: a pre- prepared external layer of the fa ⁇ ade element is inserted in a mould, next a grip supporting structure is placed on the external layer.
• the grip supporting structure consists of minimum one section, preferably a flab bar equipped, with at least one mounting eye on its end and transversely connected bars; minimum one mounting eye is inserted in special seats of the mould wall, next polyurethane foam is poured and the mould is closed until polyurethane hardens, then a ready-made self-supporting fa ⁇ ade element is taken out .
• the external layer is cleaned, degreased and heated to the temperature of 30 0 C.
• a heated mould should be used the bottom of which is the external layer of the fa ⁇ ade element.
• the internal surface of the mould is sprayed with a wax separator .
• the grip supporting structure is manufactured by means of welding and the technology of stamping in a press.
• Polyurethane foam, heated to 25 0 C is poured into a mould, its amount dependent on the optimal assumed density and thickness of the insulating layer.
• the fagade element is shaped as a self-supporting board, containing an external layer of the material selected from the group which includes: natural stone, conglomerate, gypsum, plastic and such like.
• the fa ⁇ ade element is formed into reveals, cornices, flagstones and such like.
• the advantage of the proposed solution is that the insulation together with the grip supporting structure is an integral part of the product .
• the fagade element may have an external layer made of natural stone (granite, sandstone, marble), conglomerates, gypsums and plastics.
• the assembly of a self-supporting element is much easier and by far faster than the known applied solutions .
• the formation of polyurethane in the conditions of a production house with production parameters controlled makes the adhesive forces of polyurethane and stone board reach a value which is high enough to enable the board to be suspended in an insulating layer.
• the grip supporting structure suspended in polyurethane transfers the load, onto the wall .
• the proposed technology allows the use of an external layer stone lining with a lower thickness than the one used up to now, i.e.
• an expansion joint is applied the size of which is tailored to the requirements of a given type of lining materials. This is achieved by moving the insulating layer beyond the outline of the board.
• the polyurethane insulating board is butted, and between the fagade elements there is a gap which enables thermal movement of the stone.
• the polyurethane insulator co-operates with the lining board, expanding and contracting (3-5%) as the temperature changes, without damaging its polymer structure.
• the self-supporting pre-insulated facade elements provide a cheaper alternative to the previously applied technologies.
• a combination of a stone board with a thermal insulator in the form of a formed polyurethane foam and a supporting element enables fast and reliable mounting on the wall by means of a grip supporting structure, which is currently the cheapest and best solution in terms of insulating power.
• the properties of this technology allow the fa ⁇ ade works' expenditure to be reduced by over 50%.
• the properties of polyurethane foam are incomparably better than the previously applied mineral water or polystyrene foam and do not change with time, chiefly because there is no possibility for this layer to become damp or move, and there are no thermal bridges .
• Polyurethane formed in the conditions of a production house is a chemically blocked substance (chemically inactive) . It does not release any compounds which might affect the properties of the lining board. No phenomena of blooms or stone material degradation take place. The process of ageing, degradation of polymer related only to UV radiation does not occur as the polymer is protected from light. Polyurethane insulator is also resistant to chemically aggressive environment. The proposed solution makes the works involving the use of heavy fa ⁇ ade boards similar to insulating works where polystyrene foam is applied.
• fig. 1 is a perspective view from the bottom of the fa ⁇ ade board proposed in the invention
• fig. 2 is a side view of the section of fagade board proposed in the invention
• fig. 3 illustrates a grip supporting structure of the board proposed in the invention in a perspective bottom view
• fig. 4 is a side view of the supporting structure of board grip in the second example of manufacture
• fig. 5 presents another example of manufacturing the supporting structure of board grip in a bottom view
• fig. 6 is another example of the supporting structure of board grip in a bottom view
• fig. 7 presents an arrangement of boards mounted on a building wall in a vertical section
• fig. 7a presents a detail A from fig.
• fig. 7 illustrates a detail B from fig.7 showing the mounting of the board on a fixing slat
• fig. 9 presents another example of the arrangement of boards mounted on a building wall using additional elements in a vertical section
• fig. 10 - a diagram of the first example of the arrangement of boards on a building wall in a bottom view
• fig. 11 presents an arrangement of boards in line with fig. 10a in a perspective side view.
• the fagade element presented in fig. 1 and fig. 2 has a form of a self-supporting board 1, composed of two layers: an external layer 2, which constitutes a so-called lining and insulating layer 3.
• the external layer 2 can be made of stone, conglomerate, gypsums or plastics.
• the insulating element may be shaped as a reveal, cornice, flagstone or such like.
• the insulating layer 3 contains a grip supporting structure 4, which is composed of sections 9 finished with mounting eyes 5 which protrude beyond the outline of board 1; sections 9 are fixed to the transversely located bars 10.
• the sections may have a form of flat bars, bars or such like.
• One of the bars 10 has a spacing protrusion 7.
• Board 1 presented in fig. 1 is also equipped with formed recesses 6, in which mounting eyes 5 of the neighbouring board 1 are inserted after assembly on the wall. Recesses 6 are placed in an insulating layer 2 in the line of mounting eye 5 and on the side opposite mounting eyes 5.
• the thickness of the external layer 2 ranges from 1,5 cm to 4 cm, while the insulating layer 3 is made of formed polyurethane foam the density of which reaches 80-100 kg/m3.
• the thickness of insulating layer 3 is dependant on the expected heat-transfer coefficient "U" .
• the insulating layer 3 protrudes beyond the outline of board 1, forming after the assembly of lining boards an expansion gap 15 (see fig. 7a) between external layers 2 of the neighbouring elements .
• the insulating layer 3 contains a grip supporting structure 4, from which mounting eyes 5 protrude outside. Certainly the number of mounting eyes 5 depends on the shape of fa ⁇ ade elements in the architectonic design.
• the grip supporting structure 4 presented in fig. 3 is tailored to suit particular types of material and size of the external layer, resulting from architectonic designs. Details of this structure are developed for particular designs of fa ⁇ ade, taking into account the thickness of insulating layer 3 and fa ⁇ ade elements size.
• the grip supporting structure 4 of a so-called one-side mounting is applied to fix the fa ⁇ ade elements on vertical walls, while in case of assembly on ceilings, upper parts of reveals etc. - the grip supporting structure 4 has a double-sided mounting (see fig. 4) .
• the grip supporting structure in fig. 3 has a form of two flat bars equipped with welded bars 10, which prevent the removal of flat bars from the material of insulating layer 3.
• Flat bars in the upper part of board 1 protrude beyond its outline and have mounting eyes 5 on their ends.
• Flat bars of the grip supporting structure 4 have a part bent askew towards the bottom of fa ⁇ ade element, and further bent towards its edge equipped with a mounting eye 5.
• the last of bars 10 from the side of protruding mounting eyes 5 has a spacing protrusion 7, which establishes the location of supporting structure 4 in the insulation layer 3 during the process of polyurethane formation.
• the size of spacing protrusion 7 is suited and proportional to the thickness of insulating layer 3.
• sections 9 of grip supporting structure 4 are convergent to each other at an angle dependant on the size of facade element. Mounting holes are located from the side of a greater distance of sections 9, whereas mounting eyes 5 located on the opposite side are placed under the neighbouring board that has been previously mounted on the wall.
• Fig. 6 presents another example of grip supporting structure 4, which has one section 9 protruding outside and placed diagonally on both sides .
• the mounting eyes 5 of the grip supporting structure 4 with the heads of mounting anchors 13, protruding beyond the outline of insulating layer 3, are covered with an insulating layer 3 of another board 1.
• each stone board or conglomerate board having an integrated insulating polyurethane layer 3 along with grip supporting structure 4 equipped with a mounting eye 5 is fixed to wall 11 by means of two anchors 13, which support its weight.
• preliminary sticking with adhesive agent 12 is performed, which fits the surface of board 1 to the surface of base 11.
• the integrated polyurethane layer 3 is a continuous surface without any thermal bridges.
• Thermal parameters of self-supporting facade elements result from the thickness of formed polyurethane layer that functions as an insulating layer.
• the solution plans for the use of insulating polyurethane layer 3 the thickness of which ranges from 5 cm to 15 cm, depending on the expected thermal effect.
• the self-supporting fagade boards proposed in the invention are used for thermal modernisation of the already existing facilities.
• the thickness of the insulating layer and facade material can be suited for each facility in all kinds of conditions.
• the self-supporting fagade board proposed in the invention is the only solution up to date, in which thermal bridges do not occur (except for light plasters technology) .
• a wall having such a fagade is completely shielded and protected against weather conditions . Owing to the integrated insulating layer on the surface of external layer the so- insulated wall is not penetrated by frost.
• the fagade lining should be made of granite in the form of slabs having dimensions 100 x 100 cm on a wall made of cellular concrete (24x24x48) with a 10-cm thick insulating layer providing thermal resistance of 3,33 m 2 K/W.
• the material in the form of a stone, conglomerate or gypsum board - constituting an external layer of a ready-made fagade element should be cleaned and degreased for the production process.
• the external layer is made of a stone board, it is heated to the temperature of 30°C, while the insulating layer is made in a mould.
• the dimensions of mould are suited to the size of £agade element and the internal surface of the mould is sprayed with a wax separator.
• the stage of insulating layer formation takes place in a heated multi-station mould at 30 0 C.
• a properly formed grip supporting structure is inserted in a pre-prepared stone board before flooding with polyurethane .
• the protruding mounting eyes of the grip supporting structure are inserted in special seats of the mould wall.
• the mounting eyes together with a spacing protrusion of the last transverse bar of grip supporting structure establish the position of this structure in relation to the stone board and insulating layer.
• the seats in the mould wall are used to vent the mould in the process of polyurethane formation.
• the polyurethane foam heated to the temperature of 25 0 C is poured into the mould, its amount suited to obtain the optimal assumed density and thickness of the insulating layer.
• the mould is closed for a period of time necessary to form polyurethane, which depends on the dimensions of the insulating layer and polyurethane system speed.
• the boards are stuck to the base by means of an adhesive agent in the form of glue.
• an adhesive agent in the form of glue.
• This is a well- known type of glue, commonly used when insulating a building.
• the boards are positioned and faced. Through the openings in the board grip the holes are drilled in a partition (building wall 11) , where fixing anchors 13 of a well-known type are placed, securing the boards 1 against overturning before the adhesive agent 12 hardens .
• anchors 13 are tightened to the wall. This way the fa ⁇ ade is properly fixed.
• the rule to follow is that the surfaces of insulating layer 3 of boards 1 must be closely moved to each other. After forming the first row of boards another row is arranged and mounted on the previous one, either with or without displacement, depending on the specific architectonic design.
• the upper board mounted over the existing lower board is pressed by its own weight against the lower board, which creates a possibility of arranging the boards without any gaps between insulating layers.
• Recesses 6 (see fig. 1) in insulating layer 3 in the lower part of board 1 provide a cover for mounting eyes 5 of the lower board together with the protruding heads of anchors 13.
• Adhesive agent 12 used for arranging the boards provides additional fastening, and its application allows the fa ⁇ ade front to be suited to possible irregularities of the wall surface.
• the whole weight of board 1 is transferred onto the grip supporting structure 4.
• LSR anchor which is driven and screwed home through an opening in the grip of board 1.
• a fixing slat 14 an angle section is used, the dimensions of which are suited to the thickness of the insulating layer.
• a masking (decorative) element may be mounted while fitting the fixing slat 14.
• the fixing slat 14 does no longer fulfil a supporting role and may be removed.
• the layers of adhesive agent 12, which also fix the board to the wall are spaced to provide a gap between one another . Between the external layers of the neighbouring boards there are expansion gaps 15, the size of which is selected in the stage of facade elements' manufacture and depends on the type of material of external layer 2 (lining) and architectonic requirements.
• the fixing slat 14 (see fig. 8) supporting the first row of boards must bear its weight until the glue has hardened and pins secured.
• This slat must be made from an angle section - an even-armed metallurgical profile the dimensions of which are suited to the size of the insulating layer applied in the board.
• the angle section must include the whole insulating layer. It should not overlap the lining layer (external layer of the fa ⁇ ade board) . Between the angle section edge and the stone lining a distance of ca 2- 3 mm should be maintained.
• the expansion joint is suited individually, depending on the type of lining material.
• the lower corner of the insulating layer of the first row of boards should be bevelled with a wire brush or knife in order to fit it to the internal surface of the angle section. This provides a possibility of adjusting the insulating layer surface protrusion from the wall, which is necessary to neutralise the irregularities of the building wall surface.
• the selection of angle section to be used as a fixing slat must be determined by the size of load during the assembly of the first row of boards and must take into consideration the fact that the number of pins which fix it to the wall is limited by the number of recesses formed in the insulating layer which allow pins to be mounted. Practically, with the exception of special constructions the number of mountings is limited to 2 pes/board.
• the exemplary location of the first board is shown in fig. 7a, fig. 8, in which the angle section functioning as a fixing slat 14 does not touch the external layer 2 of the board.
• the fixing slat 14 should be left after the fagade assembly as it e.g. plays the role of a decorative slat support, the fixing slat contact must be secured with a sealant e.g. silicon.
• a sealant e.g. silicon.
• Anchors 13 are placed at the height of recesses 6 formed in the insulating layer.
• the adhesive agent is put between the building wall 11 and insulating layer 3 of the board.
• Table 1.2 shows the recommended types of angle section used as a fixing slat: Table 1.2.
• the fa ⁇ ade element proposed in the invention is applied especially as a self-supporting fa ⁇ ade element, which may function as a segment of fa ⁇ ade boards' arrangement and which may be applied in the form of a board, reveal, cornice and such like.
• the proposed self-supporting board is also used when the fa ⁇ ade of a building is covered with light plaster and an underneath insulating layer made e.g. from polystyrene foam.
• insulating layer made e.g. from polystyrene foam.
• the previous insulation is removed from the stone slab and replaced with a self-supporting pre-insulated fa ⁇ ade board having a predetermined thickness of the insulating layer; by a "pre-insulated element” we understand a prefabricated element which contains an insulating layer whose thermal resistance meets the requirements specified by the designer and is additionally equipped with a grip supporting structure to secure the fa ⁇ ade element on a partition.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Finishing Walls (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (2)

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ID=39415270

Family Applications (1)

Country Status (2)

Cited By (3)

Citations (3)

• 2007
  • 2007-02-09 PL PL381729A patent/PL218408B1/pl unknown
• 2008
  • 2008-02-08 WO PCT/PL2008/000011 patent/WO2008097113A2/en active Application Filing

Patent Citations (3)

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