FACING PANEL FOR FAÇADES AND INTERIORS OF BUILDINGS

Description

[0001] The invention refers to design of facing panels, sheet and roll materials of metals and bimetal structures with relief surface.

[0002] The developed facing panel can be used for making elevations and interiors of buildings and constructions, including manufacture of wall, floor coverings and ceilings, for manufacture of frames of household appliances (refrigerators, ovens, boiler equipment, closets, etc.), for manufacture of metal furniture, for manufacture of processing equipment for trade (cashier's desks, shelf stands, refrigerator boxes, showcases, counters , etc.), for manufacture of elevators, escalators and travolators, for manufacture of frame and screen components of processing equipment, soundproof screens, also as roll material for further sticking on various surfaces, including construction materials, outside and inside walls of train cars and motor vehicles, walls of buildings and constructions, surfaces of different types of equipment.

[0003] The facing panels can be manufactured as rolls with width from 100 to 2000mm, as bands with width 100x1500mm, as sheet material of measured length with width from 500 to 2000mm and length from 2000 to 10000mm.

[0004] The facing panels can be manufactured as an integral product with different substrates, they can as well be glued to different substrates.

[0005] The facing panels may be used for manufacture of bimetal articles with upper layer thickness from 0,05 to 2mm, bottom layer thickness from 0,3 to 5mm.

[0006] Further on here the term "substance" will be used to specify the developed technical solution. In the framework of the present technical solution the indicated term "substance" means the mixture of bond and solid material particles, thereat the bond may be liquid and solid, able to fill in the cavities of a relief pattern on the product surface.

[0007] The known decorative panel (RU, useful model patent 2786), contains a metal base and a decorative element in the form of stencil painted design, thereat a tin layer, made for example in the form of anodized coating, is located between the metal base and the decorative element, thereat, the decorative cover area makes up less, than 50% of base area.

[0008] The known as well functional-decorative wall panel (RU, patent 54338) contains a fixed to wall flat base, made of metal sheet, connected by fasteners to the functional decorative elements, located at the exterior surface of the wall panel, the connected with base decorative layer, located at the wall panel exterior side, and an elastic substrate, located at the interior side of the wall panel; the decorative layer is made of sheet polymeric material, the elastic substrate is made of flexible sheet material; there are holes made in the decorative layer and in the base, the holes are located at regular pitch along vertical and horizontal axes, the fastening elements for functional elements are made with a retention head, located at the interior side of the wall panel, thereat the above mentioned holes are made along the profile, which ensures the free input of the fastening element head from the outside of the wall panel and retention of the fastening element by the said head inside the wall panel, at that the wall panel is divided into sections, which in the course of assembly form close junction along butt edges.

[0009] The drawback of both types of panels is their design complexity resulting from their multilayer character.

[0010] The known (DE, patent 2903359) metal facing panel is made of a rectangular metal sheet with bent along the whole perimeter edges, located at an acute angle to its face surface with the decorative relief, thereat the decorative relief is formed by straight and/or curvilinear oblong projections (collars), formed by method of mechanical sheet material processing with pressure, and symmetrically located with respect to a point of intersection of outside surface diagonals, the height of oblong projections being more than metal sheet thickness.

[0011] The drawback of the above described metal facing panel is its poor performance characteristics. In fact application of methods of mechanical sheet material processing with pressure for creating the decorative relief on the panel outside surface with oblong projections height exceeding metal sheet thickness impose rigid upper restrictions for metal sheet thickness and the mechanical properties of the material, applied for its manufacture. Metal sheets of high strength alloy steel with high performance parameters and thickness over 0,8 mm, which show high corrosion resistance and mechanical strength, cannot be used for manufacture of the known metal facing panel.

[0012] Also there is the known (DE, patent 3929761) metal facing panel, taken as the prototype and containing a rectangular basis, made of aluminum, which face surface has projections made of natural stone granules glued to the basis.

[0013] The drawbacks of the known technical solution are: the low lifetime of metal facing panel, as well as low performance parameters, since the known technical solution does not ensure high durability of metal facing panel.

[0014] (RU, patent 66383) can be acknowledged as the most close per its technical essence to the suggested technical solution: the metal face panel, containing metal basis with decorative elements on its outside surface, made of stainless steel, with decorative elements in the shape of cavities on its outside surface, which are filled flush or up to the level not exceeding 0,14mm from the plane of the outside surface with paint of corresponding color, applied method for filling is the method of powder coating manufacture.

[0015] The known technical solution has a limited sphere of application, determined by a simplified technology used for its manufacture (powder coating with paint, filling the cavities flush or up to the level, located no more, than 0,14 mm above the plane of the outside surface), which does not allow to reach high quality and create patterns on the products with wide range of product parameters and ensure its high consumer-oriented characteristics, including vandal-proof execution.

[0016] The technical task, solved through the implementation of the developed design, consists in creating a new type of facing panels.

[0017] The technical result, obtained by the implementation of the developed design, consists in creating the facing panel of vandal-proof execution with simultaneous decrease of the possibility for surface contamination of the facing panel and in the increase of durability in retaining the consumer-oriented characteristics.

[0018] For obtaining the shown technical result it is suggested to use the facing panel for facades and interiors of buildings, thereat its outside layer is made of corrosion resistant material and contains a relief on its surface, which cavities are filled with a substance, containing a bond and particles with hardness from 3 to 1600 units per the absolute hardness scale.

[0019] The indicated execution of the panel outside layer ensures constancy of its consumer-oriented characteristics (corrosion resistance, resistance to scratching, imperceptibility of the signs of fatty sediments, including fingerprints) in the course of at least 50 years.

[0020] The outer layer may be made of stainless steel, titan or aluminum alloy, ensuring achievement of the indicated consumer-oriented characteristics.

[0021] In some execution variants the panel is containing at least two layers, at that the outer layer is made of stainless steel, titan, aluminum alloy, and the inner layer is made of at least one material, chosen of the group: carbon steel, glass-fiber material, black-reinforced plastic, laminated paper plastic, foam aluminum, cell structure, fibrous concrete, plate, made with plant fiber application, plate made with synthetic fiber application, foam plastic, plastic, ceramic tile, ceramic granite, silicate cotton, glass foam, composite material. The presence of the indicated layers does not exclude a possibility to use at least one third layer. At least one layer of glue, serving for fastening the indicated two layers and/or for attaching the panel to a load bearing wall, may be used as the third layer. The last variant is the most probable one in case the developed facing panel is used as facing material for building structures.

[0022] The preferable relief depth makes up from 0,01 to 1,8 mm. Usage of relief elements with smaller depth is not practical, because so little quantity of the hardened substance does not prevent scratching, while usage of relief elements with bigger depth leads firstly to a possible outer layer mechanical damage, and secondly to an irrational substance waste without a positive impact on the achievement of the indicated technical result.

[0023] Particles of one material, as well as a mixture of particles of different materials may be used in the substance composition. Usage of a mixture of particles of different materials allows a certain reduction of the article self-cost without worsening its consumer-oriented characteristics.

[0024] It is preferable, while it is not exceptional, to use particles of different materials, at least one of them should be chosen of the group, containing metal, stainless steel, ferrochromium, ferronickel, corundum, fused corundum, quartz, glass, orthoclase, gypsum, mica, tiff, fluorite, tungsten carbide, molybdenum carbide, boron carbide, silicon carbide, titanium carbide, titanium nitride, boron nitride, silicon nitride, carbon nitride, boron-carbon-silicon, diamond, cuproslag, nickelslag, rear-earth metal oxide, ferric oxide, silicon dioxide, aluminum oxide, magnesium oxide, granite, ceramics, cemented oxide, hard alloy on the basis of cobalt, titan, tungsten, molybdenum, vanadium and/or borides and carbides alloys of titanium subgroup with carbides and lanthanide borides, fibers.

[0025] For retention of the substance processing characteristics the desirable mass share of the particles content in the substance should not exceed 92%.

[0026] For the most part the substance contains the bond, chosen from the group, containing fluorocarbon polymer, rubber resin, melamine, polyurethane, thermosetting polymers, epoxy resin, polyester resin, acryl resin, alkyd resin, ethyl silicate resin, epoxy ester resin, polyvinylchloride resin, silicon resin, polyphenyle siloxane resin, glyptal resin, formaldehyde resin, silicon resin, hydrocarbon resin, silicon resin , and solder alloys. The indicated list does not restrict application of other materials, ensuring achievement of the indicated technical result.

[0027] If the manufactured panels are used outside the premises it is advisable to use a bond, resistant to ultraviolet radiation action. It increases the retention period of consumer-oriented characteristic.

[0028] In particular such fluorocarbon polymers may be used as a bond, resistant to UV radiation action: TEFLON 7, FLUON, ALGOFLON F, POLYFLON M 12,14, TEFLON 8, HOSTAFLON TF 1640, POLYFLON M30, FLUON G 307, TEFLON FEP, NEOFLON FEP, TEFLON 6, FLUON CD, POLYFLON F 103, 104, TEFZEL, HOSTAFLON ET, NEOFLON ETFE, KYNAR, SOLEF, NEOFLON VDF, KEL-F, VOLTALEF, NEOFLON CTEF, TEFLON 30, FLUON AD, HOSTAFLON TF5000, POLYFLON D.

[0029] Depending on the panel application, material of used particles, depth and the relief cavities size, particles with sizes from 0,003 to 2 mm may be used.

[0030] For rendering decorative properties to the substance and to the ready facing panel, a coloring matter may be additionally introduced into the bond in the form of dyestuff, pigments.

[0031] The technological variant of mixing the soldering particles with hard materials particles (of diamond particles type) with subsequent sintering of mixture may be used for facing panels manufacture. The obtained substance is warmed up and the relief of an article of manufacture is filled up with it. Another variant is possible as well when the mixture, containing soldering particles is mixed with such particles as diamond ones and the relief cavities are filled with it and sintered.

[0032] The choice of high hardness particles is determined by high mechanical load accompanied by wear and tear at the time of the facing panels' usage. The said high mechanical load may appear as the result of vandals' activities, as well as in the course of the product exploitation in the places with increased wear - in trains, airports, in shops, for protecting surfaces from passengers' baggage and belongings and from the passengers themselves. Since the bond of usual type is a polymer with moderate hardness and wear-resistant properties, it is necessary to introduce a solid filler into the polymer bond, which will receive the load. The bigger is the size of the filler particles, the harder is the composite material, containing these particles, the higher are antifriction properties of the hardened substance. It is experimentally established, that usage of particles with hardness less than 50 as per the absolute scale does not ensure the technical result achievement.

[0033] There are two known ideal cases of the article of manufacture protection against mechanical damage - the first case is characterized by the variant, when particles of different sizes occupy the maximum volume (up to 92% of the hardened substance), and the second case is characterized by the variant, when the size of the particle itself is maximum with reference to the cavity micro relief geometrical size.

[0034] Typically, cracks in composite materials are located along the media boundaries - in the material, possessing the least fracture strength. In this case - it is a polymer-bond. Thereat it should be taken into the account, that in case the diamond particles with hardness 1600 units per absolute scale are introduced into the polymer, these diamond particles exactly will work to counteract wear and tear and will receive the load. The larger is the diamond particles quantity in the substance, and the bigger are these particles (in comparison with the receptacle - the relief cavity), the higher are the material antifriction properties, since the diamond by itself is almost the ideal abrasive - cutting tool. Besides, in such hardened substance there are less possibilities for cracks appearance in the polymer bond, because its presence is small in such a case: basically there is the diamond present in the substance, and there are few possibilities for cracks expansion in the polymer matrix (bond).

[0035] Different variations of proportions between the filler and the bond are necessary for different surfaces, for different loads. Different hardness is necessary for different materials, with different load and different abrading vandal tools. Where a metal coin is the source of destruction, the following materials may be applied: corundum, cubic boron nitride, boron carbide, titan carbide, tungsten carbide, silicium carbide. Diamond and cubic boron nitride should be used, in cases when a vandal uses a roadside stone (for example, granite).

[0036] The basic application of the developed article of manufacture will be the variant, where the following materials will be used as substrates: stainless steel, aluminum alloys, other metal alloys, as well as various products of concrete on the basis of cement, granite, ceramic granite and other ceramics, polymer concrete on the basis of polymer bonds, and also plastic articles, where the superhard particles will be embedded for wear prevention.

[0037] Further on the invention will be illustrated by the implementation samples.

1. The relief pattern with linear size of cavities 0,3-0,4 mm is deposited by a lithographic method onto the work piece, being a band of titan with thickness 0,2mm. The relief is created on the free band surface by application of a jet etching method. The plate surface is washed and dried. The substance, containing epoxy resin as the bond and corundum particles of size 0,1 - 0,3 mm, is applied to the surface with relief. The particles content in the substance makes about 85 % of mass share. Excessive substance is mechanically removed from the band surface. The article of manufacture is ready for use after polymer basis hardening (polymerization).
The conducted tests have shown, that the product surface is resistant to scratching with a coin of copper and nickel alloy, and with a key of patent lock. Fingerprints and other fatty contaminations are practically not noticeable on the surface with relief. The article of manufacture surface, used for interior trimming of the office room does not require any repair works at least within the period of 50 years.

2. The example is implemented similar to the example 1, but a band of aluminum alloy of 3,0 mm thickness is used. The value of the relief linear size makes up 0,2 - 0,3 mm. The substance contains polyester resin and diamond particles of 0,040 - 0,050 mm size. The particles content is approximately equal to 50 % mass share.
The results are similar to example 1.

3. The example is implemented similar to example 1, but a band of stainless steel of 3,0 mm thickness, glued to a heat-insulator plate of silicate cotton with thickness 80 mm is used. The value of the relief linear size makes up 0,3 - 0, 4 mm. The substance contains polyester resin and diamond particles of 0,050 -0,063 mm size. The particle content is approximately equal to 80 % mass share.
The results are similar to example 1.

4. The example is implemented similar to example 1, but a band of duralumin of 2,0 mm thickness, with a plate of foam alumina of 50mm thickness glued to its reverse side, is used. The value of the relief linear size makes up 0,8 - 1,2 mm. The substance contains rubber resin and particles of fused alumina of 0,2 -0,3mm size. The particle content is approximately equal to 70 % mass share.
The results are similar to example 1.

5. The example was implemented similar to example 4, but particles of glass powder of size 1,0 - 1,3 mm were used. Scratches from the action of a copper and nickel alloy coin and from the action of a key of the patent lock are visible on the surface. The surface will loose its commodity appeal in 5 - 6 years.

6. The relief pattern with linear size of cavities 0,4-0,5 mm is deposited by a lithographic method onto a work piece, being a band of stainless steel of 0, 2mm thickness with a piece of foam plastic of 50 mm thickness, glued to its reverse side. The rest of operations, known from example 1, are repeated. The substance, containing nickelslag particles with size 0,5-0,7 mm and polyphenyle siloxane resin with particle size about 65% mass share, is applied to the surface with relief.
The results are similar to example 1.

7. The example was implemented similar to example 6, but using the substance, containing silicium carbide particles with size 0,8 - 1,2 mm and phenolformaldehyde resin with approximately 70 % mass share particles content.

[0038] The results are similar to example 1.

[0039] Working an invention with parameters, introduced into the independent claims of the formula of invention, always results in achievement of the shown technical result.

Claims

1. The facing panel for elevations and interiors of buildings, which is distinguished for its outer layer made of corrosion resistant material, containing a relief on its outer surface, which cavities are filled with the substance containing bond and particles with hardness from 3 to 1600 units per absolute hardness scale.

2. The panel as in claim 1, wherein its outer layer made of stainless steel, titan or aluminum alloy.

3. The panel as in claim 1, which is distinguished for being made of at lease two layers, thereat the outer layer is made of stainless steel, titan, aluminum alloy, and the inner layer is made of, at least one material, chosen from the group: carbon steel, glass-fiber material, black-reinforced plastic, laminated paper plastic, foam aluminum, cell structure, fibrous concrete, plate, made with plant fiber application, plate made with synthetic fiber application, foam plastic, plastic, ceramic tile, ceramic granite, silicate cotton, glass foam, composite material.

4. The panel as in claim 1, which is distinguished by the relief depth making from 0,01 to 1,8 mm.

5. The panel as in claim 1, which is distinguished by usage of the particles of one material.

6. The panel as in claim 1, which is distinguished by usage of the particles of different materials.

7. The panel as in claim 1, which is distinguished by usage of the particles of different materials, with at least one of them chosen of the group : metal, stainless steel, ferrochromium, ferronickel, corundum, fused corundum, quartz, glass, orthoclase, gypsum, mica, tiff, fluorite, tungsten carbide, molybdenum carbide, boron carbide, cubic nitride carbide, silicon carbide, titanium carbide, titanium nitride, boron nitride, silicon nitride, carbon nitride, boron-carbon-silicon, diamond, cuproslag, nickelslag, rear-earth metal oxide, rear earth oxide, ferric oxide, silicon dioxide, aluminum oxide, magnesium oxide, granite, ceramics, cemented oxide, hard alloy on the basis of cobalt, titan, tungsten, molybdenum, vanadium and/or borides and carbides alloys of titanium subgroup with carbides and lanthanide borides, fibers..

8. The panel as in claim 1, which is distinguished by the particle content in the substance making up no more than 92% mass share.

9. The panel as in claim 1, which is distinguished by the substance containing the bond, chosen of the group, containing fluorocarbon polymer, rubber resin, melamine, polyurethane, thermosetting polymers, epoxy resin, polyester resin, acryl resin, alkyd resin, ethyl silicate resin, epoxy-ester resin, polyvinylchloride resin, silicon resin, polyphenyle siloxane resin, glyptal resin, formaldehyde resin, silicon resin, hydrocarbon resin, silicon resin , and solder alloys.

10. The panel as in claim 9, which is distinguished by usage of the bond, resistant to the ultraviolet radiation action.

11. The panel as in claim 1, which is distinguished by usage of particles with size from 0,003 to 2 mm.