WO2020149806A1 - A composite panel containing clay-based exterior coating materials and a production method in connection thereunto. - Google Patents

A composite panel containing clay-based exterior coating materials and a production method in connection thereunto. Download PDF

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Publication number
WO2020149806A1
WO2020149806A1 PCT/TR2019/050537 TR2019050537W WO2020149806A1 WO 2020149806 A1 WO2020149806 A1 WO 2020149806A1 TR 2019050537 W TR2019050537 W TR 2019050537W WO 2020149806 A1 WO2020149806 A1 WO 2020149806A1
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WO
WIPO (PCT)
Prior art keywords
clay
concrete mortar
glass fibre
composite panel
cotta
Prior art date
Application number
PCT/TR2019/050537
Other languages
French (fr)
Inventor
Ozgur UZELTURK
Original Assignee
Isiklar Insaat Malzemeleri Sanayi Ve Ticaret Anonim Sirketi
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Isiklar Insaat Malzemeleri Sanayi Ve Ticaret Anonim Sirketi filed Critical Isiklar Insaat Malzemeleri Sanayi Ve Ticaret Anonim Sirketi
Publication of WO2020149806A1 publication Critical patent/WO2020149806A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/022—Means for inserting reinforcing members into the mould or for supporting them in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/044—Water-setting substance, e.g. concrete, plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B32B2307/581—Resistant to cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • 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
    • E04C2002/005—Appearance of panels
    • E04C2002/007—Panels with the appearance of a brick wall
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/244—Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires

Definitions

  • the invention is related to a composite panel containing clay-based exterior coating and glass fibre reinforced concrete used for sound and thermal insulation in buildings and a production method in connection thereunto.
  • sheathing application is performed or insulating hollow bricks containing insulation material are used.
  • the insulation materials are attached to the exterior of the building with dowels and/or by bonding.
  • An exterior facade coating material similar to a brick, which contains an insulating layer, is mentioned in the national utility model document with the number TR2016/11045 available in the prior art.
  • High density mineral wool is used as the insulation layer in said document. It comprises a brick-like plate and an insulating layer bonded and/or fixed to each other. Tongue-and-groove joint ends are available. This product is only applicable to columns and beams.
  • glass fibre reinforced concrete panels are also used as the exterior coating material. However, the glass fibre reinforced concrete panels in prior art are composed of a single layer. Therefore, no effective insulation can be achieved.
  • the purpose of the invention is to create a composite panel, which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones.
  • Another purpose of the invention is to obtain a composite panel that is resistant to abrasion and decay.
  • the composite panel featuring a clay-based exterior cladding material developed to achieve said objectives; has a glass fibre reinforced concrete layer and a clay-based layer obtained from terra-cotta based soil.
  • the invention is an exterior cladding material with an integrated structure.
  • the production method related to the composite panel featuring a clay- based exterior cladding material developed for carrying out said objectives comprises following process steps; primarily laying the clay-based layer (2) obtained from terra-cotta based soil into the designated mould (4) made of silicone rubber material, pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil,
  • Attached Figure - 1 is the perspective view of exploded state of the layers of the composite panel (1).
  • Attached Figure -2 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).
  • Attached Figure-3 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).
  • Attached Figure-4 is the rear view of the processes step concerning laying the glass fibre mesh (3.2) on the concrete mortar (3.1).
  • Attached Figure-5 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the glass fibre mesh (3.2).
  • Attached Figure-6 is the front view of the composite panel (1) when the silicone mould (4) is removed.
  • Attached Figure-7 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).
  • Attached Figure-8 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).
  • Attached Figure-9 is in an alternative application of invention, the rear view of the processes step spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1).
  • Attached Figure- 10 is in an alternative application of invention, the rear view of the processes step pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed.
  • Attached Figure- 11 is the front view of the composite panel (1) when the silicone mould (4) is removed.
  • the invention is related to an exterior cladding material in composite structure, wherein one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil and the production method in connection thereunto.
  • glass fibre mesh reinforced concrete layer (3) which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones, is preferred.
  • Glass fibre mesh reinforced concrete layer (3) offers maximum resistance to external factors thanks to its high cement content and low permeability.
  • the composite panel (1) featuring such glass fibre mesh reinforced concrete layer (3) is obtained by pouring the concrete mortar (3.1) into the joints clearances and on to the back surface of the coating brick, laying the glass fibre mesh (3.2) onto it and finally pouring concrete mortar (3.1) and leaving for drying.
  • the composite panel (1) can also be obtained by mixing the glass fibre with the concrete mortar (3.1) with low water ratio and then leaving for drying.
  • the glass-fibre mesh reinforced concrete layer (3) in mortar form may be poured by using a spraying system. It can be used in various moulding processes as it has pouring is possible with the spraying system. Steel building materials can be used in glass fibre reinforced concrete layer (3), if desired and required. Thus, a more robust structure is obtained.
  • the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material, then the fibre- free concrete mortar (3.1) is poured into the joint clearances and on the rear surface of the clay-based layer (2). On top of that, glass fibre mesh (3.2) is laid as a cover. The concrete mortar (3.1) is poured again after the laying process is completed. The composite panel (1) prepared after the last treatment is left for one day to dry and when it is dry, silicone rubber moulds (4) are removed. Moulding can be performed according to the desired size and design. As a result, the glass- fibre mesh reinforced concrete layer (3) and the clay-based layer (2) become a composite structure.
  • Concrete mortar (3.1) used in the invention contains cement, plasticizer, silica sand and acrylic polymers.
  • the thickness of said concrete mortar (3.1) can vary between 2-12 mm.
  • the glass-fibre mesh (3.2) used in the invention Impact and crack formation in the composite panel (1) is prevented thanks to the glass-fibre mesh (3.2) used in the invention. Furthermore, the alkali resistance of said composite panel (1) is increased. In addition, the composite panel (1) is provided with high tensile strength. An almost homogenized layer is obtained by means of the glass fibre mesh (3.2). In this way, each zone of the glass-fibre mesh reinforced concrete layer (3) has the same strength.
  • the invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which is composed of following process steps; the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), laying the glass fibre mesh (3.2) on concrete mortar (3.1) (1003), pouring concrete mortar (3.1) on the mesh laid (3.2) (1004),
  • glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen.
  • the invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which comprises following process steps;
  • the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1) (1003a),
  • the clay-based layer (2) obtained from terra-cotta based soil is embedded into glass fibre mesh reinforced concrete layer (3) at the level that is intended to be seen from the top.
  • glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen.
  • concrete mortar 3.1
  • the composite panel (1) which consists of the combination of the clay- based layer (2) obtained from terra-cotta based soil and the glass fibre mesh reinforced concrete layer (3), is more effective compared to glass fibre reinforced concrete panels that are composed of a single layer, in terms of both acoustic sound insulation and strength.
  • the clay-based layer (2) used in the glass fibre mesh reinforced concrete layer (3) can be produced in any desired design and size. Also, the dimensions of the composite panel (1) may vary depending on the request and the requirements. In an alternative embodiment of the invention, composite panels (1) produced in large dimensions are supported by steel. In another alternative embodiment of the invention, the mesh is made with steel or different metals into the glass fibre mesh reinforced concrete layer (3). In this way, the composite panels (1) are not dispersed when exposed to an external impact and the damage caused is reduced.
  • the invention is related to an exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil.
  • the invention is related to a composite panel (1) featuring a clay-based exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having a clay-based layer (2) obtained from terra-cotta based soil laid into a silicone rubber mould (4), concrete mortar (3.1) poured into the joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil, a glass fibre mesh (3.2) laid on the concrete mortar (3.1) and concrete mortar (3.1) poured on the mesh (3.2) laid, the concrete mortar (3.1) featuring cement, plasticizer, silica sand and acrylic polymers and the glass fibre mesh reinforced layer (3) featuring a mesh made of steel or different metals.

Abstract

A Composite Panel Containing Clay-Based Exterior Coating Materials and a Production Method in Connection Thereunto. 5 The invention is related to a composite panel (1) featuring a clay based exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having a clay-based layer (2) obtained from terra-cotta based soil laid into a silicone rubber mould (4), concrete mortar (3.1) poured into the joint clearances and on the back side of the clay based layer (2) obtained from terra-cotta based soil, a glass fibre mesh (3.2) laid on the concrete mortar (3.1) and concrete mortar (3.1) poured on the mesh (3.2) laid, the concrete mortar (3.1) featuring cement, plasticizer, silica sand and acrylic polymers and the glass fibre mesh reinforced layer (3) featuring a mesh made of steel or different metals.

Description

A Composite Panel Containing Clay-Based Exterior Coating Materials and a Production Method in Connection Thereunto.
Technical Field The invention is related to a composite panel containing clay-based exterior coating and glass fibre reinforced concrete used for sound and thermal insulation in buildings and a production method in connection thereunto.
Prior Art
In order to provide sound and thermal insulation on the exterior facades of buildings, sheathing application is performed or insulating hollow bricks containing insulation material are used. In the exterior sheathing method, the insulation materials are attached to the exterior of the building with dowels and/or by bonding. There are reinforcement mesh and exterior sheathing lining for better adhesion of the plaster on the heat insulation material in the exterior cladding. After performing these stages, sound and thermal insulation of the building is ensured. These kinds of insulation techniques on building exterior take a lot of time and bring a material burden.
An exterior facade coating material similar to a brick, which contains an insulating layer, is mentioned in the national utility model document with the number TR2016/11045 available in the prior art. High density mineral wool is used as the insulation layer in said document. It comprises a brick-like plate and an insulating layer bonded and/or fixed to each other. Tongue-and-groove joint ends are available. This product is only applicable to columns and beams. In the prior art, glass fibre reinforced concrete panels are also used as the exterior coating material. However, the glass fibre reinforced concrete panels in prior art are composed of a single layer. Therefore, no effective insulation can be achieved.
Purpose of the Invention
The purpose of the invention is to create a composite panel, which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones.
Another purpose of the invention is to obtain a composite panel that is resistant to abrasion and decay.
Another purpose of the invention is to obtain a composite panel having the same dimensions and the same strength at all sides with the use of fibreglass mesh. Another purpose of the invention is to obtain a composite panel that allows to obtain more aesthetic and different architectural views.
The composite panel featuring a clay-based exterior cladding material developed to achieve said objectives; has a glass fibre reinforced concrete layer and a clay-based layer obtained from terra-cotta based soil. The invention is an exterior cladding material with an integrated structure.
The production method related to the composite panel featuring a clay- based exterior cladding material developed for carrying out said objectives comprises following process steps; primarily laying the clay-based layer (2) obtained from terra-cotta based soil into the designated mould (4) made of silicone rubber material, pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil,
laying the glass fibre mesh on concrete mortar (3.1),
pouring concrete mortar (3.1) on the mesh laid,
leaving poured concrete mortars (3.1) to dry,
removing the moulds (4) it dries.
Description of Figures
Attached Figure - 1 is the perspective view of exploded state of the layers of the composite panel (1).
Attached Figure -2 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).
Attached Figure-3 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).
Attached Figure-4 is the rear view of the processes step concerning laying the glass fibre mesh (3.2) on the concrete mortar (3.1).
Attached Figure-5 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the glass fibre mesh (3.2).
Attached Figure-6 is the front view of the composite panel (1) when the silicone mould (4) is removed.
Attached Figure-7 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).
Attached Figure-8 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).
Attached Figure-9 is in an alternative application of invention, the rear view of the processes step spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1). Attached Figure- 10 is in an alternative application of invention, the rear view of the processes step pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed.
Attached Figure- 11 is the front view of the composite panel (1) when the silicone mould (4) is removed.
Numbers and names of main parts mentioned in the figures are given below.
(1) Composite panel
(2) Clay-based layer
(3) Glass fibre mesh reinforced concrete layer
(3.1) Concrete mortar
(3.2) Mesh
(4) Mould
Detailed Explanation of the Invention
The invention is related to an exterior cladding material in composite structure, wherein one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil and the production method in connection thereunto. As the insulating layer, glass fibre mesh reinforced concrete layer (3) which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones, is preferred.
Glass fibre mesh reinforced concrete layer (3) offers maximum resistance to external factors thanks to its high cement content and low permeability. The composite panel (1) featuring such glass fibre mesh reinforced concrete layer (3) is obtained by pouring the concrete mortar (3.1) into the joints clearances and on to the back surface of the coating brick, laying the glass fibre mesh (3.2) onto it and finally pouring concrete mortar (3.1) and leaving for drying.
In an alternative embodiment of the invention; the composite panel (1) can also be obtained by mixing the glass fibre with the concrete mortar (3.1) with low water ratio and then leaving for drying. In another alternative embodiment of the invention, the glass-fibre mesh reinforced concrete layer (3) in mortar form may be poured by using a spraying system. It can be used in various moulding processes as it has pouring is possible with the spraying system. Steel building materials can be used in glass fibre reinforced concrete layer (3), if desired and required. Thus, a more robust structure is obtained.
The clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material, then the fibre- free concrete mortar (3.1) is poured into the joint clearances and on the rear surface of the clay-based layer (2). On top of that, glass fibre mesh (3.2) is laid as a cover. The concrete mortar (3.1) is poured again after the laying process is completed. The composite panel (1) prepared after the last treatment is left for one day to dry and when it is dry, silicone rubber moulds (4) are removed. Moulding can be performed according to the desired size and design. As a result, the glass- fibre mesh reinforced concrete layer (3) and the clay-based layer (2) become a composite structure.
Concrete mortar (3.1) used in the invention contains cement, plasticizer, silica sand and acrylic polymers. The thickness of said concrete mortar (3.1) can vary between 2-12 mm.
Impact and crack formation in the composite panel (1) is prevented thanks to the glass-fibre mesh (3.2) used in the invention. Furthermore, the alkali resistance of said composite panel (1) is increased. In addition, the composite panel (1) is provided with high tensile strength. An almost homogenized layer is obtained by means of the glass fibre mesh (3.2). In this way, each zone of the glass-fibre mesh reinforced concrete layer (3) has the same strength.
The invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which is composed of following process steps; the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), laying the glass fibre mesh (3.2) on concrete mortar (3.1) (1003), pouring concrete mortar (3.1) on the mesh laid (3.2) (1004),
leaving poured concrete mortars (3.1) to dry,
removing the moulds (4) it dries (1005).
In an alternative embodiment of the invention, glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen. The invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which comprises following process steps;
the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1) (1003a),
pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed (1004a),
leaving poured concrete mortars (3.1) to dry,
removing the moulds (4) it dries (1005). The clay-based layer (2) obtained from terra-cotta based soil is embedded into glass fibre mesh reinforced concrete layer (3) at the level that is intended to be seen from the top. In an alternative embodiment of the invention, glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen. In addition, when brick or stone products are used in exterior cladding, the clearance between the stones or bricks is filled with concrete mortar (3.1) as an additional process. Since the clearance is filled with the glass fibre mesh reinforced concrete layer (3) in the composite panel (1) production, no additional process is needed.
The composite panel (1), which consists of the combination of the clay- based layer (2) obtained from terra-cotta based soil and the glass fibre mesh reinforced concrete layer (3), is more effective compared to glass fibre reinforced concrete panels that are composed of a single layer, in terms of both acoustic sound insulation and strength.
The clay-based layer (2) used in the glass fibre mesh reinforced concrete layer (3) can be produced in any desired design and size. Also, the dimensions of the composite panel (1) may vary depending on the request and the requirements. In an alternative embodiment of the invention, composite panels (1) produced in large dimensions are supported by steel. In another alternative embodiment of the invention, the mesh is made with steel or different metals into the glass fibre mesh reinforced concrete layer (3). In this way, the composite panels (1) are not dispersed when exposed to an external impact and the damage caused is reduced.
The invention is related to an exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil. The invention is related to a composite panel (1) featuring a clay-based exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having a clay-based layer (2) obtained from terra-cotta based soil laid into a silicone rubber mould (4), concrete mortar (3.1) poured into the joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil, a glass fibre mesh (3.2) laid on the concrete mortar (3.1) and concrete mortar (3.1) poured on the mesh (3.2) laid, the concrete mortar (3.1) featuring cement, plasticizer, silica sand and acrylic polymers and the glass fibre mesh reinforced layer (3) featuring a mesh made of steel or different metals.

Claims

C L A I M S
1. A production method of the composite panel containing clay based exterior coating used for sound and thermal insulation in buildings, characterised in that; it comprises the following process steps; the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001),
pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002),
laying the glass fibre mesh (3.2) on concrete mortar (3.1) (1003), - pouring concrete mortar (3.1) on the mesh (3.2) laid (1004),
leaving poured concrete mortars (3.1) to dry,
removing the moulds (4) it dries (1005).
2. A composite panel containing clay based exterior coating used for sound and thermal insulation in buildings, characterised in that; it comprises, the clay-based layer (2) obtained from terra-cotta based soil laid into the mould (4) made of silicone rubber material,
concrete mortar (3.1) poured into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil
(3.1),
the glass fibre mesh (3.2) laid on concrete mortar (3.1) and concrete mortar (3.1) poured onto the glass fibre mesh (3.2).
3. A composite panel mentioned in Claim 1, characterised in that; concrete mortar (3.1) contains cement, plasticizer, silica sand and acrylic polymers.
4. A composite panel mentioned in Claim 1, characterised in that; the glass fibre mesh reinforced concrete layer (3) comprises mesh made with steel or different metals.
5. A production method of the composite panel containing clay based exterior coating used for sound and thermal insulation in buildings, characterised in that; it comprises the following process steps;
- the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001),
- pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002),
- spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1) (1003a)
- pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed (1004a),
- leaving poured concrete mortars (3.1) to dry,
- removing the moulds (4) it dries (1005).
PCT/TR2019/050537 2018-06-12 2019-07-08 A composite panel containing clay-based exterior coating materials and a production method in connection thereunto. WO2020149806A1 (en)

Applications Claiming Priority (3)

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TR201808409 2018-06-12
TR2019/00759 2019-01-17
TR2019/00759A TR201900759A2 (en) 2018-06-12 2019-01-17 Composite Panel Containing Clay-Based Exterior Cladding Material And A Method For Its Production

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WO2020149806A1 true WO2020149806A1 (en) 2020-07-23

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US20040065034A1 (en) * 2002-03-06 2004-04-08 Messenger Harold G Insulative concrete building panel with carbon fiber and steel reinforcement
US20090235600A1 (en) * 2008-03-21 2009-09-24 Tapco International Corporation Stone work simulation system
TR201808409U5 (en) * 2018-06-12 2018-07-23 Isiklar Insaat Malzemeleri Sanayi Ve Ticaret Anonim Sirketi Clay Based Composite Panel with Exterior Coating Material

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US20040065034A1 (en) * 2002-03-06 2004-04-08 Messenger Harold G Insulative concrete building panel with carbon fiber and steel reinforcement
US20090235600A1 (en) * 2008-03-21 2009-09-24 Tapco International Corporation Stone work simulation system
TR201808409U5 (en) * 2018-06-12 2018-07-23 Isiklar Insaat Malzemeleri Sanayi Ve Ticaret Anonim Sirketi Clay Based Composite Panel with Exterior Coating Material

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115324272A (en) * 2022-09-06 2022-11-11 郑州工大高新材料科技有限公司 Assembly type building structure-heat preservation-outer protection layer integrated composite component and preparation method thereof

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