A method for the production of a wall panel comprising an opening for a frame, and an outer wall sandwich panel

Abstract

 The invention relates to The method for manufacturing a sandwich wall panel which contains a frame opening. The invention is characterized in that an intrados profile is used which defines a frame opening and two anchoring organs are provided, and the anchoring organs are embedded in two layers of mortar, and the mortar is set to yield a sandwich wall panel in which the intrados profile is integrated, wherein between the first and the second anchoring member along the circumference of the frame opening a fire-resistant strip from mineral wool is provided. The invention also relates to a sandwich panel.

Description

[0001] The present invention relates to a method for manufacturing a wall panel which contains a frame opening.

[0002] Such a method is known in the art, in particular from DE 100 00 643. Herewith an intrados construction provided with anchoring means is placed onto a mould. Next, mortar, polystyrene and again mortar are successively applied on the mould, wherein the anchoring means are embedded in the mortar, which is subsequently set. This method provides a sandwich wall panel in which a frame construction can directly be mounted, which offers an important economical advantage.

[0003] With the known method there is a risk that the second mortar ends up under the polystyrene via gaps at the intrados which function as a casing. In other words, that the polystyrene will float on the second mortar. This risk is not unimaginable, since the heavy mortar can displace the intrados functioning as a casing.

[0004] The present invention aims to improve the known method.

[0005] To this end, the present invention provides a method according to the preamble, wherein an intrados profile is used which defines a frame opening and the intrados profile is provided with an anchoring member at its outer circumferential side, the anchoring member of the intrados profile is embedded in mortar, and the mortar is set to yield a wall panel in which the intrados profile is integrated wherein either

• the intrados profile has a second anchoring member and the intrados profile functions as a casing for the second mortar wherein the second anchoring member is embedded in the second mortar, and the second mortar is subsequently set to yield a sandwich wall panel

wherein the intrados profile is integrated;
or

• the intrados profile is connected to a frame or frame construction which is provided with a second anchoring member and the totality of the intrados profile and the frame or frame construction functions as a casing for the second mortar wherein the second anchoring member is embedded in the second mortar, and the second mortar is subsequently set to yield a sandwich wall panel wherein the intrados profile and the frame or frame construction are integrated
  or,
• a second intrados profile is provided which has a second anchoring member at its outer circumferential side and the second intrados profile functions as a casing for the second mortar in which the second anchoring member is embedded and the second mortar is subsequently set to yield a sandwich wall panel wherein the intrados profiles are integrated,

wherein between the first and the second anchoring member along the circumference of the frame opening a fire-resistant strip of mineral wool is provided.

[0006] By using a strip of somewhat compressible material, it is effectively prevented that the second mortar can reach the first mortar. Additionally, it is prevented that the hard foam catches fire, in case a fire breaks out in a construction, such as a dwelling, wherein such a panel is used. In particular stone wool or glass wool is a suitable mineral wool. The second mortar can be applied more quickly, even immediately after the application of the second layer, as a result of which production can take place more quickly. A suitable thickness of the strip depends on the resilient properties of the mineral wool used. In general, a thickness of at least 2 cm, preferably at least 3 cm is suitable. A thickness of more than 5 cm will in general not be preferred since the mineral wool does not contribute to the strength of the panel, and so the thicker the strip of mineral wool the more this strength decreases. In general, the strip is applied in the form of segments (1 for each side of the casing comprising an intrados profile). The strip is for instance glued to the casing or secured using nails. Any gaps between adjacent segments will automatically be pushed closed as a result of contact with the second layer. Furthermore, the method according to the invention makes it possible to have a frame protrude beyond the front side, without the need of making (a great deal of) adjustments. Nevertheless, a more conventional arrangement of the frame is also possible, or a frame situated at the backside of the wall panel. Furthermore, a wall panel manufactured using the method according to the invention requires less finishing, since the frame opening is already provided with an intrados profile. In the present application, with an intrados a shielding for an opening of a panel is meant which hides the interior of the panel at least partially from view, insofar that interior is not already hidden partially from view by a frame. With a rectangular opening there are usually 4 intrados, or, when a frame connects intrados at the inside and the outside of the panel with each other, 8 intrados. A lowermost intrados (after putting the panel upright) may take the form of a windowsill, and in this way further finishing thereof can be avoided. An intrados can also serve for simplifying further finishing. Thus, for instance, a lowermost intrados at the front side of the panel may readily be provided with a sill, which then can protrude beyond the front side of the panel. In the present application the term intrados profile means an element constituted from one or more intrados that can function as a casing and, optionally in cooperation with a frame and a second intrados profile, can hide the centre of a wall panel from view. In many cases an intrados profile will have a rectangular shape, but others forms, such as a circular shape, are conceivable as well. A rectangular shape can be achieved in a simple way by connecting four separate intrados, which are for instance made of wood. Alternatively, such an intrados profile may also be formed in one piece, for instance from plastic such as PVC. The frame may be a frame for a window or a door. An intrados usually has a thickness of 0.5 to 5 cm and preferably 1-3 cm, although thicker or thinner is also possible. The intrados will usually have a thickness which is at least 3 times smaller than its width (wherein with width a dimension is meant measured in the direction of the front side towards the backside of the wall panel). The anchoring member will usually be situated at a distance of between 0.5 cm and 5 cm from the front side of the wall panel.

[0007] Preferably, the anchoring member is a strip that runs along the outer circumference of the intrados profile.

[0008] Such a strip has a width (the distance over which the strip of the intrados profile extends) of for instance at least 5 mm, preferably at least 1 cm and more preferably at least 2 cm. Thus, not only a proper anchoring is ensured but also an effective barrier is provided against penetration of moisture. In the present application, with the term outer circumference, any circumference of an intrados is meant on which an anchoring member that can be anchored in the mortar can be situated, thus including a side circumference. The strip is for instance a metal, plastic or wooden strip. The strip may be coarsened, perforated or be provided with a profile in order to ensure a proper adherence to the mortar. The strip is preferably applied as a strip that runs along the circumference of the intrados profile. This also applies in the case where a frame or frame construction is provided with such a strip as an anchoring member.

[0009] Although a frame construction could be connected with the intrados profile after placement of the intrados on the mould, including after manufacture of the wall panel, , it is highly preferred that the intrados profile forms part of the frame construction, and the frame construction is integrated with the wall panel by embedding and setting.

[0010] In this way, manufacturing is simplified further. In this context the term "forms part of" means that the intrados profile can be an intrados that is connected in a detachable fashion with the frame construction, it can be an intrados that is irremovably connected with the frame construction, or the intrados profile forms part of the frame construction and forms a totality therewith. If there is more than one intrados profile, this applies to the intrados profiles independently of each other. Thus, for instance, the first intrados profile can be connected in a detachable fashion with the frame construction, whereas the second intrados profile forms an integral part of the frame construction.

[0011] According to a preferred embodiment hereof the frame construction forms part of a frame which comprises a window, and the frame comprising a window and the intrados profile is placed with the intrados profile onto the mould before the anchoring member of the intrados organ is embedded in mortar.

[0012] Thus, a method is provided which requires even less finishing.

[0013] For placement onto the mould, the intrados profile can be placed sealingly onto a casing element (dummy) in the form of a frame or plate, which is placed sealingly onto the mould, where the casing element preferably is of such little height that from the backside (i.e. the side which after application of the mortar onto the mould is turned away from the mould) at the most 2 cm of the set mortar of the front side of the wall panel is visible via the frame opening. In the scope of the present invention the term "sealingly" means that no openings are allowed that have such dimensions that mortar can flow from a location outside the intrados profile to a location situated within the intrados profile. The maximally allowable size of the openings (that is to say, gaps resulting from inadequate butting up) depends on the viscosity and thixotropic properties of the mortar or second mortar used, and will in general be less than 2 mm, such as less than 1.5 mm and for instance ca. 1 mm.

[0014] In an alternative embodiment the intrados profile is placed sealingly onto the mould, in direct contact with the mould.

[0015] Thus, an aesthetically distinguished finishing can be realized with less effort.

[0016] Preferably, the foam material is an expanded polymer. In the scope of the present invention with the term "expanded polymer" each type of polymer hard foam is meant, regardless of how it is formed. The first and the second mortar can have identical or different compositions. The second mortar is preferably a finishing mortar.

[0017] The method according to the present invention makes it possible to effectively and in a simple manner protect the expanded polymer against fire, and without affecting a proper integration of a frame construction in the wall panel, using a strip of fire-resistant material that is applied along the circumference of the frame which comprises a window, preferably prior to placing the frame comprising a window onto the mould. The fire-resistant material is for instance glass wool or stone wool.

[0018] The invention also relates to an outer wall sandwich panel which comprises a first and a second layer of set mortar and a core layer of hard foam material, where the outer wall panel has a frame opening and is provided with intrados profiles having anchoring elements which are embedded in the first and the second layer of mortar respectively, wherein between the anchoring elements a strip of fire-resistant material is present selected from stone wool and glass wool.

[0019] The hard foam material is preferably expanded polymer as defined above. Such a sandwich panel can be manufactured using the method according to the invention, can be placed very easily and requires little finishing. Any finishing at the construction site can be largely or entirely avoided. The wall panel is highly suitable as an outer wall panel. Outer wall panels according to the invention usually have a width of at least 4 metres, preferably at least 5 metres and more preferably at least 6 metres.

[0020] A preferred embodiment is characterized in that both the first and the second intrados profile are part of the frame construction, and the frame construction is integrated with the wall panel by embedding and setting.

[0021] Thus, the frame construction is very firmly anchored in the outer wall panel.

[0022] According to a preferred embodiment the anchoring member is a strip which runs along the circumference of each intrados profile.

[0023] Thus, an outer wall panel is provided which effectively and to a large extent avoids cold bridges and the penetration of moisture. The strip has a width of for instance at least 5 mm, preferably at least 1 cm and more preferably at least 2 cm.

[0024] The present invention will now be illustrated by a working example and with reference to the drawing, in which

Fig. 1 shows a top plan view of a mould; and

fig. 2a - e show in a vertical cross section various phases of a method for manufacturing a sandwich wall panel provided with a frame construction.

[0025] Fig. 1 shows a top plan view of a mould 1 on which upright walls 100 have been placed, on which mould 1 a wall panel according to the invention provided with a rectangular frame 2 comprising a window is formed.

[0026] Fig. 2a shows in a vertical cross section a detail of the mould 1 onto which the frame 2 comprising a window is placed sealingly. The frame 2 comprising a window has a frame 3, double glazing 4 as well as a first intrados profile 5 and a second intrados profile 6. In the illustrated embodiment the frame construction 3 and both intrados profiles 5, 6 are made of wood and interconnected by means of glue joints. To prevent that the frame 2 is displaced during the manufacturing of a wall panel, advantageously a dummy body A is provided which, either because of its weight or because it is connected with the mould 1, or forms part thereof, impedes displacement of the frame 2 or even makes it impossible.

[0027] The intrados profiles 5, 6 each have an anchoring strip 7 and 8, respectively which run along their outer circumference.

[0028] After sealingly placing the frame 2 comprising a window onto the mould 1, first mortar 9 is applied onto the mould 1, wherein the first anchoring strip 7 is embedded in the first mortar 9. Before the first mortar 9 is set, a plate of polystyrene 10 is placed onto the unset first mortar 9, after which a second mortar 11 is applied onto the polystyrene 10, wherein the second anchoring strip 8 is embedded in the second mortar 11. Hereafter, the yet unset mortar 9, 11 is allowed to set to yield a largely finished outer wall panel in which the intrados 5, 6 are integrated. If more than 1 plate of expanded polymer 10 is used, these can be interconnected, for instance by glueing. This will usually take place after application of the expanded polymer onto the first mortar 9, in order to avoid that air gets trapped under the expanded polymer 10.

[0029] To remove air bubbles captured under the expanded polymer 10, an underpressure can be applied. This is, for instance, possible by covering the totality of the mould and panel with a PVC foil, and subjecting the space under the foil to an underpressure. For that matter, it is noted that, although the presence of bubbles may not be desirable, especially the large bubbles are disadvantageous, and especially the large bubbles, should they even occur, can be removed properly with the underpressure technique described above. The air can escape between adjacent plates of expanded polymer or via holes that have been provided in the plates for this purpose. These holes can be made, for instance, by using, optionally hot, needles. Another advantageous method to prevent air from getting trapped under the expanded polymer in the method according to the invention, is using strips of hard foam having a width of 50 cm or less, such as 40 cm or less. Advantageously, plates are cut to strips and the strips are placed with a cut face (thus, transverse to the original surface of the plate) on the first mortar.

[0030] In the scope of the present invention the term "sealingly" means that no openings are allowed that have such dimensions that first or second mortar can flow from a location outside the first intrados profile 5 to a location situated within the intrados profile 5. The maximally allowable size of the openings (that is to say, gaps resulting from improperly butting up of the first intrados profile 5 and the mould 1) depends on the viscosity and thixotropic properties of the first mortar 9 or second mortar 11 used, and will in general be less than 2 mm, such as less than 1.5 mm and for instance ca. 1 mm. The mortars used in the present invention further are lowshrinkage, that is to say that during setting they present a shrinking or swelling of no more than 1%, preferably less than 0.5% and more preferably less than 0.2%. An example of a suitable mortar is TM5203 (Tillman, Megchelen, The Netherlands), which is prepared according to the instructions of the manufacturer. The outer wall panels according to the invention will preferably comprise reinforced set layers of mortar. The reinforcement is for instance in the form of reinforcement mats, such as hot dip galvanized wire mesh Casanet (wire thickness 2.05 mm; maze 50 x 50 mm; Van Rooy en Co, Rotterdam, The Netherlands). This is pressed in the layer of mortar, which was subsequently levelled off. Instead of wire mesh, also for instance a woven glass fibre mat can be used, such as is available designated as Glasgitter wfsl GW545 (Romar-Voss, Roggel, The Netherlands). The second mortar 11 is advantageously a self-levelling mortar, such as ABS 340 of Beamix (Eindhoven, The Netherlands). This mortar contains fibres which function as a reinforcement. In order to prevent drying out, the mortar 11 can be covered, for instance with PVC foil, during setting.

[0031] In the embodiment shown in fig. 2c and further, the frame 2 comprising a window has a fire-resistant strip 12 along its outer circumference, for instance of stone wool. Here, Rockwool having a thickness of 3 cm (soft or semi-hard pressing; Lapinus, Roermond, The Netherlands) is used. This prevents, according to the invention, that second mortar 11 can end up under the expanded polymer 10 (fig. 2d), here polystyrene (EPS 150 SE, thickness 200 mm, Unidek, Gemert, The Netherlands), as a result of which the properties of strength of the finished panel could be affected or the panel possibly even would have to be rejected.

[0032] The second intrados profile 6 preferably has an end 13 that is, as seen from the front side, tapered or rounded off, wherein that much second mortar 11 is applied onto the polystyrene 10 that the second mortar 11 at least reaches that tapered or rounded off end 13. Thus, in a simple manner an aesthetic attractiveness is achieved, wherein the part of the second intrados profile 6, which as seen from the front side of the outer wall panel protrudes beyond the backside of the outer wall panel, is not perceived as being poorly finished, whereas the exact thickness of the layer of second mortar 11 is less critical. This applies mutatits mutandis also for embodiments wherein only a first intrados is present which extends from the front side to the backside, and thus functions with the method as a casing for both the first mortar and the second mortar and is integrated in the wall panel after setting. The setting normally takes 16 hours, before the mould together with the outer wall panel is placed vertically and the outer wall panel formed can be left for further setting for about 1 week.

[0033] Usually, at least the glass of the frame 2 comprising a window will be provided with a protective foil (not shown). Although a frame construction 3 after placement of the intrados onto the mould 1, including after manufacture of the wall panel, could be connected with the intrados profile 5, it is greatly preferred that the intrados profile 5 forms part of the frame construction 3, and the frame construction 3 is integrated with the wall panel by embedding and setting.

[0034] Thus, manufacturing is further simplified. The intrados profile 5 can be an intrados profile 5 that is connected in a detachable fashion to the frame construction 3, it can be an intrados profile 5 that is irremovably connected to the frame construction 3, or the intrados profile 5 forms part from of the frame construction 3 and forms 1 totality therewith. If there is more than one intrados profile, this applies for the intrados profiles 5, 6 independently of each other. Thus, for instance, the first intrados profile 5 can be connected in a detachable fashion to the frame construction 3, whereas the second intrados profile 6 forms an integral part of the frame construction 3.

[0035] According to a preferred embodiment hereof, the frame construction 3 forms part of a frame 2 which comprises a window, and the frame 2 comprising a window which comprises at least the one intrados profile 5 is placed with the one intrados profile 5 onto the mould 1 before the anchoring member 7 is embedded in first mortar 9, which in practice will be removed after placement of the outer wall panel. Also the intrados profiles 5, 6 and the frame construction 3 can be provided with such a protective foil. In this way, any splashes of mortar and other dirt can be readily removed.

[0036] By using profile mats (such as for instance profile mat 2/70 PO available from Reckli (Herne, Germany)) on the bottom of the mould, an outer wall panel can be manufactured wherein the front view side requires no finishing or only minimal finishing and yet still looks attractive. In case the frame rests on the profile mats, a sufficient sealing has to be provided for, such as already set forth above.

Claims

1. A method for manufacturing a wall panel which contains a frame opening, wherein an intrados profile is used which defines a frame opening and the intrados profile is provided with an anchoring member at its outer circumferential side, the anchoring member of the intrados profile is embedded in mortar, and the mortar is set to yield a wall panel in which the intrados profile is integrated, wherein the mortar before it is set is covered with a plate of expanded polymer, onto the plate of expanded polymer a second mortar is applied,
wherein either

- the intrados profile has a second anchoring member and the intrados profile functions as a casing for the second mortar wherein the second anchoring member is embedded in the second mortar, and the second mortar is subsequently set to yield a sandwich wall panel wherein the intrados profile is integrated;
or

- the intrados profile is connected to a frame or frame construction which is provided with a second anchoring member and the totality of the intrados profile and the frame or frame construction functions as a casing for the second mortar wherein the second anchoring member is embedded in the second mortar, and the second mortar is subsequently set to yield a sandwich wall panel wherein the intrados profile and the frame or frame construction are integrated
or

- a second intrados profile is provided which has a second anchoring member at its outer circumferential side and the second intrados profile functions as a casing for the second mortar in which the second anchoring member is embedded and the second mortar is subsequently set to yield a sandwich wall panel wherein the intrados profiles are integrated,

wherein between the first and the second anchoring member along the circumference of the frame opening a fire-resistant strip of mineral wool is provided.

2. The method according to claim 1, wherein the anchoring member is a strip that runs along the circumference of the intrados profile.

3. The method according to claim 1 or 2, wherein the intrados profile forms part of the frame construction, and the frame construction is integrated with the wall panel by embedding and setting.

4. The method according to claim 3, wherein the frame construction forms part of a frame which comprises a window, and the frame comprising a window and the intrados profile is placed onto the mould before the anchoring member is embedded in mortar.

5. The method according to any of the preceding claims, wherein the intrados profile is placed sealingly onto the mould, in direct contact with the mould.

6. The method according to any of the preceding claims, wherein both the first and the second intrados profile are part of the frame construction, and the frame construction is integrated with the wall panel by embedding and setting.

7. Outer wall sandwich panel which comprises a first and a second layer of set mortar and a core layer of expanded polymeer, where the outer wall panel has a frame opening and is provided with intrados profiles having anchoring elements which are embedded in the first and the second layer of mortar respectively, wherein between the anchoring elements a strip of fire-resistant material is present selected from stone wool and glass wool.

8. Outer wall sandwich panel according to claim 7, wherein the anchoring member is a strip which runs along the circumference of each intrados profile.

Drawing