RU2452827C1 - Wall panel with protective-decorative finishing and method of its manufacturing - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: wall panel with a protective-decorative finish comprises a bearing concrete and front layer, including a substrate attached to a bearing layer, a decorative layer made of a mixture of natural stone crumbs and aqueous dispersion of acrylic polymer, a protective sealing layer made of a mixture of sand with fraction of 0.1-0.6 mm or stone crumbs and/or glass granules with size of 0.1-1 mm with aqueous dispersion of acrylic polymer, and arranged between the substrate and the decorative layer, besides, to increase adhesion, the front layer is attached to the bearing layer of the panel with metal fastening elements of various shape.

EFFECT: invention makes it possible to increase strength of a panel and to increase the overhaul period of facade cover operation.

11 cl, 8 dwg

Description

The invention relates to the production of building materials and can be used for the manufacture of panels with protective and decorative finishes for walling (wall panels, loggias) in industrial, civil and other types of construction.

Currently, to improve the quality and variety of decoration of facade surfaces of buildings, decorative coatings based on polymer binder and stone chips have been used. Applying these coatings to already constructed low-rise buildings does not cause difficulties. When using such coatings on multi-storey buildings, special measures are necessary, therefore, it is advisable to finish during the manufacture of exterior wall panels directly in factories. However, the tight binding of finishing operations to the technological cycle of panel production imposes significant restrictions both on the technology of applying decorative coatings and on the characteristics of the applied polymer compositions.

Known wall panel with a protective and decorative finish, containing the supporting concrete and front layer, comprising a mixture of a polymer binder and crumbs of natural stone (see RF patent No. 2132916, class E04C 2/26 from 01/27/98).

A disadvantage of the known panel is the insufficient adhesion of the decorative layer to the carrier and the fact that the polymer binder is not sufficiently resistant to weathering. Under the influence of alternating temperatures, the adhesion of the decorative layer to the carrier may decrease, or it may break.

There is a method of manufacturing a wall panel with a protective and decorative finish, in which a mixture for the front layer, including a polymer binder and a crumb of natural stone and a mixture for the carrier layer, is successively laid into the mold (see RF patent No. 2132916, class E04C 2/26 from 27.01 .98).

The disadvantage of this method is that it is applicable for the manufacture of only decorative cladding panels with a supporting layer of fine concrete. In the manufacture of large-sized panels with a bearing layer of heavy concrete with large aggregate when laying concrete mix, the decorative layer of the panel laid on the bottom can be destroyed. In addition, the intense vibration impact on the concrete mixture, necessary for compaction of the bearing concrete layer, can destroy the not yet hardened decorative layer and lead to the penetration of cement paste on the front surface of the panel. Sustaining for several hours the decorative layer in the mold until it reaches the required strength under the conditions of factory production is impossible, as it will lead to a decrease in the turnover of molds and a decrease in output.

The technical result when using the present invention is to increase the adhesion strength of the front layer to the carrier layer of the panel and the possibility of manufacturing panels with decorative and protective finishes, in which the bearing layer of concrete contains coarse aggregate. An additional technical result is to protect the bearing concrete layer from the influence of adverse climatic and atmospheric influences of the environment, to increase the overhaul period of operation of facade coatings.

The technical result is achieved in that in a wall panel with a protective and decorative finish containing a supporting concrete and face layer, including a mixture of a polymer binder and natural stone chips, the face layer includes a substrate attached to the carrier layer and a protective-sealing layer located between the substrate and a decorative layer, while the front layer is attached to the carrier layer of the panel by fasteners.

And also the fact that the substrate is made of woven or non-woven synthetic, such as geotextiles, or mineral, such as fiberglass, or vegetable, such as cotton fabric, or a combined material.

And also the fact that the protective sealing layer is made of a mixture of sand fractions of 0.1-0.6 mm, or stone chips, and / or glass granules with a size of 0.1-1 mm with a polymer binder.

And also the fact that the polymer binder is made from an aqueous dispersion of acrylic polymer.

And also by the fact that the front layer is attached to the carrier layer of the panel with fasteners made of metal plates with a thickness of 0.4-0.8 mm.

And also the fact that the metal plates have a U-shaped cross section, and the plate shelves are serrated and bent from the wall so that the angle between them and the horizontal plane is 95-135 °.

And also the fact that the metal plates are star-shaped with the number of teeth from 4 to 8, bent at an angle of 95-135 ° from the plane of the central part of the plate.

And also by the fact that the front layer is attached to the carrier layer of the panel by fasteners made in the form of a lattice having a U-shape and made of metal rods with a diameter of 0.7-1.2 mm with a mesh size of 5-15 mm, and the lattice shelves bent from the wall so that the angle between them and the horizontal plane is 95-135 °.

And also the fact that the tops of the teeth and rods of fasteners at a distance of 1-2 mm from the tops are bent outward at an angle of 130-150 ° to the main part of the teeth and rods.

The technical result - the possibility of manufacturing panels with a protective and decorative finish, in which the concrete bearing layer contains coarse aggregate, is also achieved by the fact that in the method of manufacturing a wall panel with a protective and decorative finish, in which the face layer and the mixture for the carrier layer are successively laid into the mold the formation of the front layer is carried out on the basis on which the substrate material is laid out, after which a protective-sealing layer is applied to the substrate, dried, after drying, the protective-sealing layer of nan the decorative layer is settled, dried, after which the finished face layer is placed in the mold and poured with a mixture for the carrier layer of the panel.

The technical result is also achieved by the fact that after placing the face layer in the form, fasteners are installed on it and fix them to the face layer by dynamic influences.

In the drawings of figures 1, 2 shows a wall panel and the composition of the front layer. The panel consists of a bearing concrete 1 and a front layer attached to it with fasteners (decorative and protective finish) 2 layers. The purpose of the front layer is to protect the bearing concrete layer from the influence of adverse climatic and atmospheric influences of the environment. The front layer 2 includes a substrate 3 attached to the concrete concrete layer, a protective-sealing layer 4 and a decorative layer 5. The substrate 3 may be made of woven or non-woven synthetic, such as geotextile, or mineral, such as fiberglass, or vegetable, such as cotton, or combined material. The purpose of the substrate is a flexible reinforcing base (frame) for applying subsequent layers.

A protective-sealing layer 4 is applied to the substrate 3. The protective-sealing layer is made of a mixture of sand of a fraction of 0.1-0.6 mm with an aqueous dispersion of acrylic polymer, or of a mixture of stone chips, or glass granules with a size of 0.1-1 mm s aqueous dispersion of acrylic polymer. The purpose of the protective-sealing layer is to protect the decorative layer during molding from leakage of cement milk from the side of the bearing concrete layer, as well as the substrate material during operation, from exposure to ultraviolet radiation and other aggressive environmental factors. At the same time, the protective-sealing layer serves as the basis for applying a decorative layer 5 made of stone chips and / or glass granules with a size of 0.3-3.0 mm and an aqueous dispersion of acrylic polymer. The decorative layer is intended solely to give the wall panel an attractive appearance. The composition of the decorative layer includes larger particles than the composition of the protective-sealing layer, due to which the structure of the decorative layer is not dense enough, and moisture and ultraviolet radiation can easily penetrate through it. In this case, the metal fastening element 6 is covered on one side by concrete of the carrier layer 1, and on the other hand, by the substrate 3.

In the description of the invention, three variants of metal fasteners of various shapes are given.

Figure 3 shows a variant of a fastener from a metal plate of a U-shaped cross section with oppositely directed teeth 8, the tips of the teeth have bends 9.

Figure 4 shows a variant of the fastener of a bent metal plate having a star shape. The tops of the teeth 8 have bends 9.

Figure 5 shows a variant of the fastener from a bent U-shaped lattice. The ends of the rods 12 have bends 9.

Figure 6 shows a section of the fastener and the angles at which the teeth 8 (rods 12) and the tips of the teeth 9 are bent.

Figure 7 shows the principle of fixing the fastening element 6 to the substrate 3. After the dynamic load 13 is applied, the element 6 deforms, and it moves from position A to position B. The arrow 14 indicates the direction of movement of the tips of the teeth 9.

On Fig shows an enlarged node fixing the fastener 6 to the substrate 3 and the direction of movement of the 14 vertices of the teeth 9.

The manufacturing technology of the wall panel with a protective and decorative finish is as follows. To simplify the application, the protective-decorative (front) layer of the panel is made separately in the form of a carpet. The carpet is laid in the mold before concreting, metal fasteners are fixed to it, and then it rests on the carrier layer of the panel.

First, the substrate material 3 is laid out and fixed on the base. After fixing the substrate 3 on the base, a protective sealing layer 4 is applied to it and dried. The protective-sealing layer 4 prevents the penetration of cement paste through the material of the decorative layer 5 when pouring into the mold a concrete mixture, which subsequently forms the concrete layer 1. After the protective-sealing layer has dried, the decorative layer 5 is applied and dried. After the decorative layer 5 has dried, the finished front layer 2 in the form of a carpet is removed from the working pallet, turned over, placed in a mold for the manufacture of a wall panel, where metal fasteners are fixed to it, and the concrete mixture of the carrier layer 1 of the panel is poured.

To fix the substrate 3 to the carrier layer 1, metal fasteners 6 are used. The fasteners 6 are made of metal plates 0.4-0.8 mm thick. The fastening elements 6 may have a different shape.

1. Metal plates can have a U-shape (figure 3), and the plate shelves are serrated and bent from the wall 7 so that the angle between them and the horizontal plane is 95-135 °.

2. The metal plate may be in the form of a star (figure 4) with the number of teeth from 4 to 8, bent from the plane of the central part of the plate 10 at an angle of 95-135 °.

3. Fasteners can be made in the form of a lattice (figure 5), having a U-shaped shape and made of metal rods with a diameter of 0.7-1.2 mm with a mesh size of 5-15 mm, and the shelves of the lattice are bent from the wall 12 so that the angle between them and the horizontal plane is 95-135 °.

The tops of the teeth (rods) 9 of the fasteners 6 at a distance of 1-2 mm from the tops are bent outward at an angle of 130-150 ° to the main part of the teeth (rods).

The principle of fastening is the same for all variants of metal fasteners. After laying the finished face layer 2 in the form, the metal fasteners are tightly installed with all the tips of the teeth on the surface of the layer, a dynamic load 12 is applied to them, and they are deformed. During deformation, sharp edges due to a small bending of the ends of the 9 elements are cut into the substrate 3 and move along the protective-sealing layer 4 in direction 14, but do not pierce it. The deformation is sufficient for reliable fastening of the metal element to the front layer 2 and for the free flowing of the mortar part of the concrete mixture under these elements.

The application of the present invention allows to increase the adhesion strength of the front layer to the carrier layer of the panel through the use of fasteners. In addition, the implementation of the front layer of the proposed components protects the bearing concrete layer from the influence of adverse climatic and atmospheric influences of the environment, increases the frost resistance of the front layer and increases the overhaul period of the facade coatings.

The manufacture of panels with a decorative protective finish in the form of a front layer, including a substrate and a protective and sealing layer made of a mixture of a polymer binder and sand, allows the carrier layer of the panel to be made of heavy concrete containing coarse aggregate without fear of damage to the face layer from various technological influences in the process panel production.

The application of these methods will make it possible to produce a decorative coating separately from the technological lines of the plant where reinforced concrete products, including wall panels, are produced, increase the turnover of forms and expand the variety of types of facade decoration.

Claims (11)

1. A wall panel with a protective and decorative finish, containing the supporting concrete and face layers, and the face layer includes a decorative layer made of a mixture of polymer binder and stone chips, characterized in that the face layer includes a substrate attached to the bearing layer, and a protective a sealing layer located between the substrate and the decorative layer, while the front layer is attached to the carrier layer of the panel by fasteners. 2. The wall panel according to claim 1, characterized in that the substrate is made of woven or non-woven synthetic, such as geotextiles, or mineral, such as fiberglass, or vegetable, such as cotton fabric, or a combined material. 3. The wall panel according to claim 1, characterized in that the protective sealing layer is made of a mixture of sand fractions of 0.1-0.6 mm or stone chips and / or glass granules with a size of 0.1-1 mm with a polymer binder. 4. The wall panel according to claim 1, characterized in that the polymer binder of the decorative and protective sealing layer is made of an aqueous dispersion of acrylic polymer. 5. The wall panel according to claim 1, characterized in that the fasteners are made of metal plates with a thickness of 0.4-0.8 mm 6. The wall panel according to claim 5, characterized in that the metal plates are U-shaped in cross section, the plate shelves being serrated and bent from the wall so that the angle between them and the horizontal plane is 95-135 °. 7. The wall panel according to claim 5, characterized in that the metal plates are star-shaped with the number of teeth from 4 to 8, bent at an angle of 95-135 ° from the plane of the central part of the plate. 8. The wall panel according to claim 1, characterized in that the front layer is attached to the carrier layer of the panel with fasteners made in the form of a lattice having a U-shape and made of metal rods with a diameter of 0.7-1.2 mm with a mesh size 5-15 mm, and the shelves of the lattice are bent from the wall so that the angle between them and the horizontal plane is 95-135 °. 9. The wall panel according to claims 6-8, characterized in that the vertices of the teeth and rods of the fasteners at a distance of 1-2 mm from the vertices are bent outward at an angle of 130-150 ° relative to the main part of the teeth and rods. 10. A method of manufacturing a wall panel with a protective and decorative finish, in which the face layer and the mixture for the carrier layer are successively laid in the mold, characterized in that the formation of the face layer is carried out on the base on which the substrate material is laid out, after which the protective the sealing layer is dried, after drying, a decorative layer is applied to the protective-sealing layer, dried, after which the finished face layer is placed in the mold and poured with a mixture for the carrier layer of the panel. 11. The method of manufacturing a wall panel according to claim 10, characterized in that after placing the face layer in the form, fasteners are installed on it and fix them to the face layer by dynamic influences.

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