U.S. patent application number 12/892268 was filed with the patent office on 2011-09-22 for construction plate suitable for a tile support.
This patent application is currently assigned to WEDI GMBH. Invention is credited to Stephan Wedi.
Application Number | 20110225918 12/892268 |
Document ID | / |
Family ID | 42317831 |
Filed Date | 2011-09-22 |
United States Patent
Application |
20110225918 |
Kind Code |
A1 |
Wedi; Stephan |
September 22, 2011 |
Construction Plate Suitable for a Tile Support
Abstract
A stacked construction plate, including a core layer, which is
equipped at least on one flat side with a coating that serves as a
support layer. The support layer includes at least three layers,
namely a thin transition mortar layer, which is attached to the
core layer, a non-woven glass fiber layer and a connection layer,
which is made from compression-resistant, hardened coating mortar
having a smoothed surface.
Inventors: |
Wedi; Stephan; (Emsdetten,
DE) |
Assignee: |
WEDI GMBH
Emsdetten
DE
|
Family ID: |
42317831 |
Appl. No.: |
12/892268 |
Filed: |
September 28, 2010 |
Current U.S.
Class: |
52/385 |
Current CPC
Class: |
E04F 15/182 20130101;
E04C 2/288 20130101; E04C 2/26 20130101 |
Class at
Publication: |
52/385 |
International
Class: |
E04F 13/09 20060101
E04F013/09 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 17, 2010 |
DE |
20 2010 003 760.3 |
Claims
1. A multi-layered construction plate, which is in particular
suitable for a tile support, comprising: a core layer having at
least on one flat side with a coated layer that serves as a support
layer, wherein the support layer comprises at least 3 layers,
namely a thin transition mortar layer, which is attached to the
core layer, a non-woven glass fiber layer, and a connection layer,
made from pressure-resistant, hardened coating layer having a
smoothed surface.
2. The construction plate according to claim 1, wherein the core
layer is resistant to moisture and comprises a polymer foamed
material selected from the group including EPS polystyrene foamed
material, XPS polystyrene foamed material, or polyurethane foamed
material.
3. The construction plate according to claim 1, wherein the
material for core layer is made of a construction material that is
suitable for dry construction, but that is not resistant to
moisture, selected from the group including gypsum plaster boards
including the GKB, GKF, GKP and GKS type, as well impregnated
gypsum plaster boards of the GKBI and GFKI type.
4. The construction plate according to claim 1, wherein that core
layer comprises pressed glass wool or pressed stone wool.
5. The construction plate according to claim 1, wherein the core
layer is a honeycomb board, and wherein the honeycomb is
manufactured from plastic material or from a paper mass.
6. A construction plate according to claim 1, further comprising a
support layer on the top side and a reinforcement layer on a bottom
side, which is provided with a wide-meshed woven grid or a grid
structure on the bottom side.
7. The construction plate according to claim 1, wherein a coating
mortar of a connection layer is poured on in liquid form, and is
later leveled out and smoothed under the effect of the force of
gravity so that it hardens in this form.
8. The construction plate according to claim 1, wherein the basic
material of the coating mortar of the connection layer is selected
or mixed from lime mortar, gypsum mortar or cement mortar.
9. The construction plate according to claim 1, wherein the basic
material of the coating mortar of the connection layer is selected
or mixed from loam or from gypsum for construction material.
10. The construction plate according to claim 1, wherein the basic
material comprises a commercially available filler admixture, a
hardened reaction resin, preferably epoxy resin having 2
components.
11. The construction plate according to claim 1, wherein the
compressive strength of the connection layer, measured individually
according to the DIN EN 13892 standard, is at least 25
N/mm.sup.2.
12. The construction plate according to claim 11, wherein the
compressive strength of the connection layer, measured individually
according to the DIN EN 13892 standard, is between 30-50
N/mm.sup.2.
13. The construction plate according to claim', wherein the
connection layer can be coated with mortar adhering to tiles or
with another adhesive material without leveling and smoothing.
14. The construction plate according to claim 1, wherein the
connection layer can be coated with: basic materials that do not
contain a solvent; with paint coat materials; and with covering
layers means without leveling and smoothing.
15. The construction plate according to claim 1, wherein the
non-woven glass fiber layer has a surface coating weight amount of
100 g/m.sup.2 at the most.
16. The construction plate according to claim 1, wherein the
thickness of the transition mortar layer is between 0.1 and 2.5
mm.
17. The construction plate according to claim 1, wherein the
non-woven glass fiber layer is fully covered by the connection
layer (7).
18. The construction plate according to claim 1, wherein the
non-woven glass fiber layer is fully covered by the connection
layer with the exception of at least one part in the edge region of
the construction plate.
19. The construction plate according to claim 1, wherein it is
equipped with a reinforcement band in the area of the side edge in
impacted overlapping locations of construction plates when the
plates are arranged next to each other.
20. The construction plate according to claim 1, wherein a groove
is created on the side edge of the construction plate running along
the side edge, wherein a tongue is arranged along the side edge so
that construction plates which are arranged next to each other can
form a connection consisting of a groove and a tongue.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of German Utility Model
No. 20 2010 003 760.03, filed Mar. 17, 2010.
BACKGROUND
[0002] Embodiments of the invention relates to a multi-layered
construction plate, which is in particular suitable for a tile
support, comprising a core layer which is equipped at least on one
flat side with a coated layer that serves as a support layer.
[0003] The support layer can be equipped in the same manner on both
sides. However, it is also possible that one side, in this case the
reverse side, is equipped with a reinforcing layer which is made of
cement mortar and in which is embedded a wide-meshed woven
grid.
[0004] Construction plates are known consisting of a core layer
made of moisture-resistant foamed material which are provided on
both sides with a reinforcing layer made from cement mortar and a
reinforcement consisting of a wide-meshed glass fiber woven grid.
Similar plates are sold by the applicant as WEDI construction
plates.
[0005] It has been turned out that a disadvantage with such
structural plates including a floor tile is that the front side,
which is to be provided with a tile or other plate material, must
be smoothed and leveled first in order to ensure that a
sufficiently smooth surface will be achieved. In any case, it was
not possible to simply leave out the woven reinforcement without
losing as a result a desirable strength of the mortar layer.
[0006] The goal is therefore to modify construction plates
according to prior art as mentioned above so as to achieve a
sufficient strength also on the visible side, which ion the other
hand so smooth and strong that it is suitable for coating with
ceramic plates, tiles and other coatings customary in floors and
dry constructions without additional smoothing or leveling.
[0007] The goal is achieved with a plate, wherein [0008] the
supporting layer comprises at least three layers, namely [0009] one
thin transitional mortar layer, mounted on the core layer, [0010] a
non-woven layer of glass fibres, [0011] a connection layer made of
pressure-resistant, hardened coating mortar which has a smoothed
top surface.
[0012] This kind of said support layer can be also deployed on both
sides of such a core layer.
BRIEF DESCRIPTION OF THE DRAWING
[0013] The present invention will be more readily understood from
the detailed description of embodiments thereof made in conjunction
with the accompanying drawing of which FIG. 1. is a a schematic
representation of a construction plate consistent with an
embodiment of the present invention.
DETAILED DESCRIPTION
[0014] Reference will now be made in detail to at least one
embodiment of the present invention, examples of which are
illustrated in the accompanying drawings, wherein like reference
numerals refer to the like elements throughout. The embodiment(s)
is/are described below to explain the present invention by
referring to the FIGURE.
[0015] Layers that are essentially suitable for core layers of this
type are preferably core layers which are moisture-resistant and
made from polymer foamed material and which can be selected from
the group including EPS polystyrene foamed material, XPS
polystyrene foamed material, or polyurethane foamed material.
[0016] The core layer on the other side can be selected as a
construction material suitable for dry constructions, which,
however, is not moisture resistant, for example from the group of
gypsum plaster boards including the GKB, GKF, GKP and GKS types of
boards, as well impregnated gypsum plaster boards of the GKBI and
GKFI type.
[0017] Another technical possibility is when the core layer is made
from pressed glass wool, or from pressed stone wool, or from a
honeycomb board, wherein the honeycomb is manufactured for example
from a plastic material or from a paper mass.
[0018] A particularly well integrated connection layer will be
achieved when the coating mortar material of the connection layer
is poured on in fluid form and it is then leveled out by the effect
of the force of gravity so that it hardens in this form.
[0019] It is preferred when the basic material of the coating
mortar of the connection layer is selected or mixed from lime
mortar, gypsum mortar or cement mortar.
[0020] As an alternative, the basic material of the coating mortar
of the connection layer can be selected or mixed from loam or
gypsum for construction material. Under the term "loam" is
understood clay which has yellow or brownish color and a more or
less rich content of quartz grains or quartz powder, which can also
contain lime, mica or similar impurities.
[0021] The basic material can be a hardened reaction resin which is
mixed with a filler, preferably an epoxy resin which has 2
components. When a reaction resin is employed, the resistance to
pressure of the connection layer can be significantly increased
when compared to conventional mortar layers. The goal is to achieve
a compressive strength of the connection layer, measured
individually according to DIN EN 13892, of at least 25 N/mm.sup.2,
preferably 30-50 N/mm.sup.2.
[0022] The composition of the mortar and of the reaction resin is
adjusted so that the connection layer can be coated with mortar
adhering to tiles or other adhesive material without smoothing or
leveling after hardening. The coating capability without smoothing
and leveling should be achieved also with a connection layer and
basic materials which do not contain solvent, with paint coating
materials and with covering layer means.
[0023] The thickness of the non-woven glass fiber layer is
preferably adjusted to create a thin layer, which is to say that
the non-woven glass fiber layer has a surface weight amount of 100
g/m.sup.2 at the most.
[0024] The thickness of the transition mortar layer is preferably
in the range from 0.1 to 2.5 mm.
[0025] The construction plate is preferably a non-woven glass fiber
layer which is fully covered by the connection layer. However, one
part of the area in the edge region may be excluded from this
covering.
[0026] In order to simplify the handling of the construction plate,
it is proposed to equip the construction plate with a reinforcement
band in the area of the side edge in impacted overlapping locations
of construction plates when the plates are arranged next to each
other.
[0027] It is also possible to create a groove on the side edge of
the construction plate running along the side edge so that a tongue
is arranged along the side edge, wherein construction plates which
are arranged next to each other can form a connection consisting of
a groove and a tongue.
[0028] FIG. 1 indicates a schematic representation of an embodiment
and it is not according to correct scale. The FIGURE shows a
cross-section of a construction plate provided with layers which
can be selected according to an embodiment of this invention.
[0029] A core layer 1 is made of an insulating, rigid material. In
this case it is a layer that is manufactured from extruded
polystyrene foam, which is covered on the reverse side (here below)
with a reinforcing layer 2 made of cement mortar, and in which a
wide-meshed woven grid 3 or grid structure is embedded.
[0030] On the opposite front side of the core layer 1 is arranged a
coating which labeled as support layer 4. The support layer 4
comprises a transition mortar layer 5, which has a thickness of
about 2.0 mm and which is made from cement mortar having the same
composition as the cement mortar of the cement mortar layer 2 on
the bottom side.
[0031] On the transition layer 5 is deployed a non-woven glass
fiber layer 6 with a surface coating weight amount of about 50
g/m.sup.2. Commercially available glass fibers can be used in this
case which have the length of 2 to 20 mm and a thickness of 0.2 to
1 mm.
[0032] On the glass fiber tile layer 6 is attached a connection
layer 7, which has a thickness of 1 to 5 mm and which is made of a
curable cement mortar or a 2-component mixture consisting of an
epoxy resin and a filler. The connection layer was originally
poured on in liquid form, and it was then leveled and smoothed by
the effect of the force of gravity so that it hardened in this
manner. The result is a smooth and unstructured top surface area on
which work can be performed without additional smoothing and
leveling.
[0033] Typically, an adhesive layer 8 is applied to the connection
layer 7, to which individual tiles 9 can then be glued.
[0034] Although selected embodiment(s) of the present invention
has/have been shown and described, it is to be understood the
present invention is not limited to the described embodiment(s).
Instead, it is to be appreciated that changes may be made to the
disclosed embodiment(s) without departing from the principles and
spirit of the invention, the scope of which is defined by the
claims and the equivalents thereof.
* * * * *