RU2651850C1 - Thermal insulating composite facade panel, method of its preparation and use of thermal insulating composite facade panel - Google Patents

Abstract

FIELD: construction materials.

SUBSTANCE: invention relates to heat-insulating composite facade panels. Thermal insulation composite facade panel consists of facade panel and frame, preferably made of metal, which are irreversibly fixed to each other through insulating layer. Insulation layer consists of foam, which during foaming process irreversibly connects facade panel with frame. In this case, foam material is foamed polystyrene polyurethane, consisting of two plastics: rigid polyurethane foam and expanded polystyrene foam. Also method of preparing heat-insulating composite facade panels is described, variants of heat-insulating composite front panel and use of heat-insulating composite front panel.

EFFECT: technical result consists in development of ready-to-use thermally insulated composite panel and in development of permanent connection of facade panels with layer of thermal insulation and with panel fixation system.

16 cl, 4 dwg, 1 tbl

Description

The object of this invention is a ready-to-use heat-insulating composite facade panel, a method for preparing and using a heat-insulating composite facade panel for simultaneous installation of the facade and thermal insulation of buildings.

Currently, building facades are usually covered with various types of plasters. However, rising energy prices and new legal regulations stimulate investment in the thermal insulation of buildings. The most common technology for thermal insulation of external walls is the so-called "light wet" method. When using this method, foamed polystyrene panels are fixed to the walls of the building and mechanically mounted using special rods passing through the insulating layer. After that, a layer of glue is applied to the boards made of expanded polystyrene, which completely covers the layer of expanded polystyrene, on which a reinforcing mesh (most often fiberglass) is installed, which is subsequently covered with another layer of glue. At the end, this insulated and prepared wall of the building is covered with a thin layer of plaster. The price of the facade obtained in this way is acceptable for the construction market, but the service life of this type of facade is limited. In addition, this method is a multi-stage and technologically complex process that must be performed by properly trained personnel (insulation installers).

At the same time, there is a significant market segment for durable facades made from natural or artificial materials, sandstone, various types of marble, granite or basalt, as well as from imitation of these stones. Facade panels made of these materials have a thickness of 12 to 40 mm. The large weight of these panels requires the use of a system of gratings and mechanical loops that can withstand weight up to 400 kg per 1 m ^{2 of} the facade surface. When using this type of facade, thermal insulation made of mineral wool or expanded polystyrene is located under the shields. At the same time, it should be at a distance from the mounting frame and hooks for fixing the panel. However, with this method, thermal bridges are formed that severely violate the insulating properties of building facades. Due to the high absorption capacity of the heat-insulating materials used and the absence of moisture diffusion through the monolithic cladding sheets, ventilated facades should be used in which the cladding sheets will be located at a distance of 1 to 4 cm from the insulating material. Thus obtained air gap allows you to dry wet insulation. At the same time, the ventilation channel formed in the air gap enhances long-term convection processes, which impairs the insulation properties of the facade.

This situation can be improved if used as a facade lining, shields made of fiber cement or ceramic materials such as gres, clinker, terracotta, etc. Shields made of these materials have a thickness of 6 to 12 mm. This allows you to use a thinner system of mounting frames and suspensions, which reduces heat loss. You can also use shields with a larger surface, which, for aesthetic reasons, are more often chosen by architects. However, most often, the use of ventilated facades is still required.

At the same time, another method that is used for the production of facades with a long service life is to install insulation, for example, foam polystyrene panels, on the wall of the building, followed by coating the walls so insulated with light facade tiles. However, this method requires applying them to the surface of foamed polystyrene using the adhesion technique using special adhesives and cementing gaps between the panels. Adhesives that can be found on the building materials market have a limited life and, at the same time, a relatively high price.

Fixing relatively heavy tiles onto a soft base, which is the surface of a foam polystyrene shield, carries the risk of deforming the surface of the entire facade. Moreover, water falling into the gaps carries the risk of weakening the fixation of facade tiles as a result of freezing in the winter season.

The invention and the first application by the Italian company LAMINAM of deep sintering technology for pulverized rock crystal, which allows the production of large ceramic panels with typical dimensions of 1000 × 3000 mm and a thickness of 3 mm, revolutionized the market for building materials. Currently, this technology has been improved, which allowed the production of panels with a thickness of 2 mm. These panels can be painted in any color at the sintering stage, as a result of which the highest aesthetic properties can be obtained. In addition, the low thickness of this type of panel allows for further weight reduction and simplification of the mechanical suspension system.

Ceramic panels with a thickness of 3 to 10 mm are currently fixed on metal suspensions without interacting with heat-insulating materials in ventilation systems, while the panels are mounted on a complex supporting structure attached to the heat-insulating layer by means of permanent elastic adhesive. Facade panels are fixed after installation of heat-insulating elements, fixed to the supporting structure on the walls of the building, by qualified personnel in accordance with the recommendations and instructions of the supplier of adhesive systems. As a result, the efficiency of mounting panels with glue mainly depends on atmospheric conditions during their installation. Moisture, low temperature and dustiness can adversely affect adhesive bonding strength.

At the moment, a method for fixing ceramic panels 2 mm thick to a supporting structure or directly to a heat-insulating layer has not yet been developed. This is due to the fact that panels of this thickness are too fragile and susceptible to damage, and they cannot be mounted on a support structure using adhesive systems. However, all attempts to develop a technology for fixing directly to a layer of heat-insulating material were unsuccessful, since very thin panels and, in particular, panels with a large surface, after fixing are subjected to deformation in various ways due to the difference in thermal expansion of the joined materials, which leads to a significant decrease in adhesion panels of heat-insulating material and, as a result, to its disconnection.

Thus, in the field of facades with a long service life, there is a need for ready-to-use structural panels, which are also heat-insulating facade panels, as well as a need to develop a method for permanent fixing of facade panels, especially panels with a small thickness and a large surface, to the heat-insulating panel and to the system of its fastening to the wall of the building with the creation of a heat-insulated facade panel ready for use.

Thus, the purpose of this invention is to develop a ready-to-use thermally insulated composite panel that will simultaneously combine three elements:

- a ceramic panel that performs protective and decorative functions;

- a layer that performs the function of thermal insulation; and

- a system for fixing a thermally insulated facade panel on the walls of a building.

Another objective of this invention was to develop a permanent connection of facade panels with a layer of thermal insulation and with a system for fixing the panels, this method allows the production of ready-to-use, heat-insulated composite facade panels.

These goals were achieved through the development of thermally insulated composite facade panels and the method of their preparation.

Thus, an object of the present invention relates to heat-insulating composite facade panels, characterized in that they consist of a front panel and a frame, preferably made of metal, which are irreversibly fixed to each other through an insulating layer, the insulating layer consists of foam, which during foaming irreversibly connects the front panel to the frame, while the foam is a foamed polystyrene polyurethane, consisting of two plastics: rigid polyurethane foam and foamed wow polystyrene.

Facade panels are best selected from the group consisting of ceramic panels, panels made of natural or artificial stone, glass, panels made of metal or alloys, panels made of wood, panels made of wood or plywood that imitate wood, panels made of fiber cement, drywall.

The preferred option is the production of ceramic facade panels.

The preferred thickness of the front panel is a range from 0.1 mm to 10 cm.

The preferred thickness of the insulating layer is from 4 to 25 cm, more preferred is 8-16 mm, and most preferred is 10-14 mm.

Another object of the invention is a method for preparing heat-insulating composite facade panels, characterized in that it consists of several steps:

- on the bottom of the open form, preheated to a temperature of 10-100 ° C, put the front panel,

- the mold is closed with a high-strength panel, on the surface of which the finished frame is mounted,

- after which foam material is introduced into the mold, which is expanded polystyrene polyurethane, consisting of two plastics: rigid polyurethane foam and expanded polystyrene, as a result, the expanding foam fills the internal space of the form and remains in it until the end of the polymerization and curing process,

- and when the polymerization and curing process is completed, the mold is opened by lifting the lid and pushing the side walls of the mold.

A preferred embodiment of the mold for use in the method of the invention is a mold whose side walls are coated with a material that does not adhere to polymerizable foam material, for example, Teflon, Tarflen.

A preferred embodiment for opening the mold is to supply high pressure compressed air between the walls of the panel and the mold by means of channels formed in the mold walls.

The preferred option is to withstand prepared panels at a temperature of 10-30 ° C for 2-30 hours.

The object of the invention is also a thermally insulated composite facade panel made using the above method.

This invention also relates to the use of a thermally insulated composite facade panel in accordance with the invention for the simultaneous installation of the facade and thermal insulation of buildings, especially high-rise buildings.

An embodiment of a thermally insulated composite facade panel in accordance with the specified invention is shown in the drawing, where:

FIG. 1 shows a thermally insulated composite facade panel in accordance with the invention, shown in perspective;

FIG. 2 is a thermally insulated composite facade panel in accordance with the invention, shown in section, taken along line AA in FIG. one; and

in FIG. 3 and 4 are photographs of a thermally insulated composite facade panel in accordance with the invention after conducting a flammability test.

The heat-insulated composite facade panel in accordance with the invention shown in the drawings is made using a known low-pressure molding process of a mixture of raw materials to form foamed plastics, preferably foamed polyurethane, polyester and polystyrene, or mixtures and composites of these foamed plastics, for example, foamed polystyrene polyurethane. At the bottom of an open form made of a well-known material of high strength and stiffness, such as steel or cast iron, whose shape reflects the shape of the finished panel, put the front panel. Facade panels can be made from all known facade materials. These may include ceramic panels, panels of natural or artificial stone, glass, panels of metal or alloys, panels of wood, panels of wood or plywood imitating wood, panels of fiber cement, drywall or the like. The thickness and type of panels should be chosen so that their weight per unit area does not cause stresses that would exceed the strength of the used heat-insulating foam material, while the indicated strength was obtained at the end of the production process, and non-observance of these recommendations can cause damage to the foam material, communication failure facade shield and its detachment from the panel. The calculation of the maximum thickness of the foam material corresponding to this condition is carried out using well-known engineering methods. The minimum thickness of the used facade panels is limited for aesthetic reasons due to the possible exit of foam through the panel layer. The thickness of the panels caused by this condition is from 0.1 mm for sheets of metal to 10 mm for panels made of fiber cement and other light materials. The side walls of the mold are coated with a material that does not adhere to the polymerizable foam material, for example, Teflon, Tarflen, etc. The mold is closed by a high-strength shield, which was selected using well-known design principles, while it can withstand the pressure of expanding and polymerizing foam material. The finished metal frame is fixed to the surface of the lid. Fixing is carried out using permanent magnets mounted on the lid of the mold or using other known methods. Foam comes out of the nozzle of mixing devices and dispensers that can be found on the market. The inside of the mold is pre-heated at a temperature of 10 to 100 degrees Celsius. The heat-insulating foam during expansion fills the inner part of the mold and is firmly fixed to the facade panel, as well as to the frame, this is achieved due to the forces of adhesive interaction. The foam remains in shape until the polymerization and curing process is complete. When the polymerization and curing process is completed, the mold is opened by lifting the lid and pushing the side walls of the mold. This process is accompanied by the supply of high pressure compressed air between the walls of the panel and the mold by means of small channels formed in advance in the mold walls. After removing the mold and cooling to ambient temperature, the heat-insulating composite facade panel is ready for use.

The solution proposed by these inventors is a heat-insulating composite facade panel consisting of three elements that perform three different functions. The first element is a metal frame, preferably lightweight and made of steel, it is a supporting structure and at the same time an element of the system for attaching the panel to the wall of the building. The second element is facade panels, such as ceramic panels, panels made of natural or artificial stone, glass, panels made of metal or alloys, panels made of wood, panels made of wood or plywood imitating wood, panels made of fiber cement, drywall or similar materials, preferably - ceramic panels, for example, panels manufactured by the Italian company Laminam S.P.A. The choice of ceramic panels, as well as their preferred options depend on the specific characteristics of this material. The surface of these panels is very durable and resistant to mechanical stress, in addition, it is absolutely chemically passive. Such properties of ceramic panels make them resistant to atmospheric conditions and provide ease of cleaning (resistance to graffiti). In addition, ceramic panels of this type are characterized by an absorption capacity close to zero, and therefore, complete frost resistance. At the same time, they are an excellent decorative material with exceptional aesthetic properties.

The element, which combines a metal frame and facade panels, is the third component - a layer of insulating material such as foamed polystyrene-polyurethane, PSUR. Particular preference is given to the insulating material - expanded polystyrene-polyurethane, hereinafter referred to as PSUR. This material is a composite consisting of two plastics: rigid polyurethane foam (PUR) and expanded polystyrene (EPS). This is their physical mixture. In the proposed embodiment, these three components are combined in one process: as a result of pressing, adhesion and simultaneous cross-stitching of the foamed polyurethane during expansion of the polystyrene, a very strong connection of the facade panels with a system of mechanical suspensions and with heat-insulating material, PSUR, is formed.

The creation of a prototype of heat-insulating panels by these inventors confirms the possibility of integration in one process (in one step) of three different materials, such as steel, ceramic panel and insulating material. A key element was the selection of the PSUR composite as the material that connects the ceramic panels to the mechanical suspension system. This composite is one of a small number of polymeric materials with very good mechanical properties, which at the time of creation has excellent adhesion properties, ensuring the bonding of this composite material into a single whole. Thus, the use of the PSUR composite makes it possible to create permanent joints between the support frame and ceramic panels during one process - during the synthesis of foamed polyurethane and expansion of polystyrene granulate. PSUR composite is much cheaper than rigid polyurethane foams, which is also very important and of great importance for the building materials market.

Another advantage of the solution proposed by these inventors is that, unlike the previously described multi-stage technique for the production of building facades, the use of panels of this type makes it possible to create heat-insulating walls of a building in one step. Thus, the facade of the building is simultaneously covered with an insulating layer and a protective ceramic layer. Moreover, the installation of such panels can be carried out by workers after their general training using basic construction tools.

Thus, the proposed solution is unique, it was not previously known to other manufacturers of building materials. Thanks to this decision, it will be possible for the first time to introduce a panel on the world market of building materials, which simultaneously includes a fixing system, an insulating layer and ceramic panels of small thickness, for example, 2 and 3 mm, which will allow creating building facades with a long service life, very attractive appearance and excellent performance.

PSUR composite description

The combination of two very different materials into one composite material always holds many secrets. As a result of such a combination, it is possible to obtain material in which the disadvantages of its two components will be combined, while it is also possible to obtain new material with unsuccessful or especially valuable properties. This happened when creating a combination of two well-known materials: rigid polyurethane foam (PUR) and expanded polystyrene (EPS).

EPS (polystyrene foam) is a cheap insulating material that is very often used in the construction industry. Its key advantages are ease of installation and the price of this type of insulation. However, this solution is not without drawbacks, for example:

- low resistance to mechanical damage;

- relatively high operating costs associated with the restoration of mechanical damage, with plastering and painting the facade;

- under the influence of elevated temperatures, EPS panels melt and completely lose their heat-insulating and mechanical properties;

- EPS panels used in the construction industry are self-extinguishing panels, while they are not combustible, for this reason they cannot be used in high-rise buildings;

- very low resistance to chemicals, in particular to solvents contained in adhesives;

- EPS, due to open channels in the structure, is not a completely waterproof material. Thus, it is at risk of freezing and freezing out of water that condenses in the misting zone.

The thermal conductivity coefficient of EPS depends on the density and production technology; it varies from 0.032-0.042 W / mK (Elzbieta Radziszewska-Zielina: Przeglqd Budowlany, 4/2009).

Rigid polyurethane foam (PUR) does not have all the disadvantages that exist with EPS panels. It is an excellent thermal insulation material, which also has very good mechanical properties. Its density is close to EPS, while the thermal conductivity coefficient PUR is in the range from 0.023 W / mK (closed cells) to 0.035 W / mK (open cells). Despite all the advantages, the use of these materials in the construction industry is limited by their price. The cost of panels made of rigid polyurethane foam is several times higher than similar panels made of expanded polystyrene. It is the cost of this type of insulation that significantly limits its use in housing (Elzbieta Radziszewska-Zielina: Przeglqd Budowlany, 4/2009).

The composite polymer material, PSUR, is a combination of two plastics, its characteristics are given above. This is a new material with special characteristics, which in the future will be widely used in the technology of production of insulating and building materials. This material was developed by the Polish company HIT Konsulting, and the composite preparation process was used for patent protection in a series of patent applications (PL 387535, PL 395886, PL 396151, PL 396152). PSUR preparation consists in the simultaneous synthesis and cross-linking of rigid polyurethane foam (a two-component process) and the joint foaming (co-expansion) of the polystyrene granulate used to produce expanded polystyrene. Thus obtained material is a mixture of two plastics and a composite, showing new characteristics, which were not in any of the components that make up the finished product. The combination of two so different materials - expanded polystyrene and rigid polyurethane foam, during the process described above, allows you to create a special material that combines the unique advantages of rigid polyurethane foam and a significant reduction in cost without significantly affecting the properties of the foam material.

A composite of polyurethane and polystyrene, obtained by simultaneous cross-stitching and joint foaming, is an excellent adhesive material located close to porous coatings (brick, concrete, natural or artificial stone, ceramics), as well as from a metal frame. This property of the material, which, in combination with the process of simultaneous pressing at elevated temperatures during the preparation of composite thermally insulated panels in accordance with the invention, allows it to be used as a material for fixing the steel suspension system and ceramic panels to each other. In this way, no gaps are formed in which rainwater or condensed water could fall

in high humidity conditions. Moreover, there is no phenomenon of water getting into the gaps, which carries the risk of weakening the fixation of facade tiles as a result of freezing in the winter season.

Since rigid polyurethane foam is a PSUR matrix, this material usually retains its excellent properties: it has mechanical stability, does not crack and does not crumble. At the same time, it has the necessary structural properties that allow ceramic facade panels to be mounted not only in the form of ventilated facades, but also in the form of panels that are fixed and mounted directly to the outer walls of insulated buildings.

The PSUR composite has a low moisture absorption coefficient. As a result, there is no significant diffusion of moisture into the outer insulating layers. In winter, freezing of water does not occur in closed cells of insulated foam. Therefore, the proposed design of facade panels with built-in thermal insulation made of PSUR material is not exposed to the destructive influence of frozen water. Thus, there is no destruction of thermal insulation due to absorption of water in the insulating layer and the possibility of breaking the binding of the outer ceramic layer.

Since the PSUR composite is based on cross-linked plastic, it also has a very high chemical resistance. This allows you to use a wide range of very strong industrial adhesives, for example, at the time of fixing this material to the wall of the building or when fixing individual panels to each other during the installation of the facade.

In addition, the composite construction of the PSUR material makes it possible to obtain a material having good parameters for attenuating sound. It drowns out sound much better than single-phase materials such as polystyrene foam and polyurethane foam. In this area, only mineral wool has the best properties.

Despite the fact that the PSUR heat-insulating material is a combustible material in this class: “fire-retardant” - panels of this type are highly fire-resistant, since their installation guarantees the absence of oxygen penetrating into the insulating material. Moreover, the polyurethane matrix, annealed at temperatures above 140 ° C, does not collapse, but forms a specific slag, which continues to hold the external ceramic layer due to its low thickness and, consequently, due to its low weight. Which, in turn, continues to cut off the thermal insulation from the incoming oxygen and guarantees safety during a possible rescue operation or during the fight against fire.

As in the case of polyurethane foam, composite PSUR, due to its mechanical and chemical properties, is resistant to various types of microorganisms, fungi and rodents.

The main characteristics of this material are given in the following table:

Description of thermal insulation panel

These inventors created a prototype of a heat-insulating composite facade panel. Creating the necessary form and manufacturing such a panel turned out to be a difficult structural and technological task, but it was shown that it is possible to produce a heat-insulated composite facade panel in one step, consisting of a system of mechanical suspensions, a facade panel and a layer of composite thermal insulation material, which is at the same time is a building and heat-insulating material that binds individual elements.

Separate heat-insulating facade panels are fixed to the walls of the building with the help of expanding bolts. The design of the mechanical suspension system allows for positional adjustment of individual panels in relation to walls and in relation to successive facade elements. Individual elements of the facade - insulated facade panels - are not fixed to each other, but only connected using a half overlap connection, the following panels are superimposed on the previous ones. A gap of 1 cm is left between the wall of the building and the rear wall of the panel, which can be filled with lightweight polyurethane foam. This solution allows you to place heat-insulating facade panels on a building with an uneven wall surface and prevent the formation of cold bridges at the junction of the individual panels.

In order to prevent water from entering between the facade elements, as well as to maintain a very attractive appearance of the obtained facade, in the proposed solution, the welded joints between the individual panels of the facade panels are cemented and sealed using the appropriate adhesive masses.

Double-sided sealing of the PSUR insulation layer with polyurethane foam inside and with adhesive between the individual facade panels leads to the fact that the material has no contact with oxygen. However, the slow destruction of organic material, such as PSUR, which can occur over many years of use, is impossible. This allows you to use this type of panels and the described method of their installation to create building facades with a long service life.

The presented design of heat-insulating facade panels and the method of their installation in the form of a facade on the walls of the building also have several additional advantages:

- quick and easy installation of finished insulated facade panels;

- the ability to create a facade by staff with only one general training and basic building tools;

- the design of the system of mechanical suspensions and the use of a system of lead-out plates makes it possible to easily align and move individual panels relative to each other in order to adapt the facade thus created to different sizes of the walls of the building;

- individual heat-insulated facade panels in the proposed fixation system are mechanically fixed to the walls of the building and to each other, while excluding the possibility of separation or falling of individual elements of the facade of the building;

- a system of mechanical suspensions hidden behind thermal insulation prevents the formation of cold bridges;

- a layer of thermal insulation material PSUR with a thickness of 10-14 cm, and in particular 12 cm, corresponds to a layer of expanded polystyrene of approximately 15-20 cm used in energy-efficient homes;

- lower vapor permeability in comparison with traditional facades.

Advantages of the Invention

1. High thermal insulation: energy savings and low heating costs.

2. Strength and long service life: longer periods of operation (without the need for repairs), higher resistance to atmospheric conditions, mechanical and biological damage, easy maintenance, fire resistance is higher than that of expanded polystyrene panels and the possibility of use on the walls of high-rise buildings.

3. Composite design: ease of installation, reduced installation time and cost, economic transportation efficiency, industrialization of production insulation processes (no risk of insufficient insulation due to manual preparation at the construction site: lack of supervision, poor atmospheric conditions, lack of qualified workers, that is, installers isolation).

4. Very low moisture absorption: increase the service life of the building by reducing the destruction of insulation, as well as by reducing cracking or detachment of the facade panels due to freezing or freezing of water that has condensed in the fogging zone and a longer period of operation.

5. Decrease in wall thickness: removal of air voids / gaps that are necessary in ventilated facades, the possibility of producing much thinner insulating walls, continuous improvement of the aesthetic properties of architecture due to the reduction of window niches, the possibility of obtaining larger effective zones of the system along its contour.

6. Very low weight of large panels: reduced wall loads, increased safety during installation and operation, increased safety in the event of a fire, earthquake or landslide, less transportation costs.

7. Higher aesthetic properties: the ability to create unlimited patterns and colors of facades, the ability to use large insulating panels that are in demand on the market, the ability to achieve the effect of a modern facade that is resistant to dirt and graffiti.

8. Attractive price: the ability to reduce the cost of a high-quality facade with a long service life, while maintaining high aesthetic properties and excellent thermal insulation properties.

An example of a thermally insulated composite facade panel in accordance with this invention is shown in FIG. 1 and FIG. 2.

The panel consists of a front ceramic shield 1 with a thickness of 3 mm, a width of 50 cm and a height of 150 cm, a steel frame 3, the structure of which is shown in FIG. 1 and FIG. 2, which are attached to each other using an adhesive layer of foam material PSUR 3 with a thickness of 12 cm. This panel was prepared as follows.

On the bottom of the open steel mold, a ceramic sheet of Laminam 1 of the above dimensions was placed. The side walls of the mold were coated with Teflon. The mold was closed with a high-strength lid, on the surface of which a steel frame, shown in FIG. 2. After this, foam was applied through the nozzle of the mixing and application system. The inside of the mold was pre-heated to a temperature of about 50 degrees Celsius. The heat-insulating foam during expansion filled the inside of the mold and was firmly fixed to the ceramic sheet, as well as to the steel frame, this is achieved due to the forces of adhesive interaction. The foam remained in shape until the polymerization and curing process was completed. When the polymerization and curing process was completed, the mold was opened by lifting the lid and sliding the side walls of the mold. This process was accompanied by the supply of high pressure compressed air between the walls of the panel and the mold by means of small channels formed in advance in the mold walls. After removing the mold and cooling to ambient temperature, the heat-insulating composite facade panel is ready for use.

The resulting heat-insulating composite façade panel was tested for fire resistance in accordance with the standard procedure of the Research Institute of Building, Warsaw.

The object of the test was a facade panel made of Laminate sheets with built-in insulation made of PSUR material. Dimensions, mm:

Leaf Laminam 1500 × 500 × 3 PSUR insulation 1510 × 510 × 120

The test bench was a window with a test panel, which was located above the window. The flammability test reproduced the natural fire in the building, next to the window. An assumption was made that the combustion time would be 30 minutes, which is enough to obtain a certificate authorizing use in the construction industry. The fire was obtained by burning a measured amount of wood to get the energy supplied during the procedure, as well as a predetermined amount of heat. Dry birch firewood was taken for burning. During combustion, it turned out that this amount of wood is not enough to maintain fire during the study period. For this reason, an additional portion of wood was added after 15 minutes, and then another portion after 30 minutes of dough. The back wall and side walls of the panel were insulated with mineral wool to prevent direct burning of PSUR insulation material. The outdoor temperature was approximately 10 ° C.

To measure the temperature, a Conbest pyrometer, model testo 845 was used. To measure low and high temperatures, thermographic cameras, models V20 and V50 were used, with their help the temperature distribution was estimated. The progress of the process was recorded using photographic images and video.

Due to its excellent fire resistance, the test time was increased to 50 minutes. The recorded thermograms reflected the temperature distribution on the surface of the panel under study. On the rear side of the panel, there was no significant increase in temperature, which reached a maximum of about 20 ° C. The maximum temperature (485.2 ° C) was obtained at the bottom edge of the panel.

After the test, the panel was cut along the center line. In FIG. Figure 3 shows a photograph of a panel cut along the center line, according to which it is clear that fire does not extend to the inner surface of the panel, only the outer layer of PSUR material is carbonized, which does not lead to the destruction of the panel, weakening of the metal frame and separation of the outer layer of the facade. Despite the fact that a high temperature gradient caused a rupture of the surface of the ceramic sheet, no detachment of fragments from the panel was noted, since they are firmly fixed to the insulating material. In FIG. 4 shows a section of a panel showing individual components.

This test panel passed the test with burning for 45 minutes. No flame propagation was observed. None of the fragments of the Laminam sheet fell from the panel. No weakening of the fixation of the steel frame was noted. The partially burnt rear surface of the panel was caused by poor thermal insulation of the rear surface. When fixing to the wall of the building, this effect was not observed due to the lack of contact with open fire.

From the point of view of fire resistance, the greatest danger is caused by high temperature gradients, which lead to cracking of the surface of the ceramic sheet. The gaps formed at that moment provide air access to the insulating material. Despite the very low weight of Laminam tiles, these tiles remain fixed to the slag, which was partially formed when the PSUR material was burned. For this reason, oxygen supply is limited and further burning of the insulating material is not possible. This protects the entire facade structure from the spread of fire and allows the use of heat-insulating panels in high-rise buildings.

Claims (16)

1. A heat-insulating composite facade panel, characterized in that it consists of a facade shield and a frame, preferably made of metal, which are irreversibly fixed to each other through the insulation layer, the insulation layer consists of foam, which, during foaming, irreversibly connects the facade panel to the frame while the foam is a foamed polystyrene polyurethane, consisting of two plastics: rigid polyurethane foam and foamed polystyrene. 2. The heat-insulating composite facade panel in accordance with paragraph 1, characterized in that the facade panels are selected from the group comprising ceramic panels, panels of natural or artificial stone, glass, panels of metal or alloys, panels of wood, panels of wood or wood plywood, fiber cement panels, drywall. 3. The heat-insulating composite facade panel in accordance with paragraph 1, characterized in that the facade shield is made of ceramic sheet. 4. The heat-insulating composite facade panel in accordance with paragraph 1, characterized in that the facade shield has a thickness of 0.1 mm to 10 cm. 5. Heat-insulating composite facade panel in accordance with paragraph 3, characterized in that the foam consists of foamed polystyrene-polyurethane, PSUR. 6. Heat-insulating composite facade panel in accordance with paragraph 4, characterized in that the foam consists of foamed polystyrene-polyurethane, PSUR. 7. Heat-insulating composite facade panel in accordance with any of paragraphs. 1, 2, 5, 6, characterized in that the thickness of the insulating layer is from 4 to 25 cm, more preferred options are 8-16 mm, and most preferred options are 10-14 mm. 8. The method of preparing heat-insulating composite facade panels, characterized in that it consists of several steps: on the bottom of an open form, preheated to a temperature of 10-100 ° C, a facade panel is placed, with an offset, the form is closed with a high-strength panel, on the surface of which the finished frame is mounted, after which a foamed material is introduced into the mold, which is a foamed polystyrene polyurethane, consisting of two plastics: rigid polyurethane foam and expanded polystyrene, as a result of expanding A clear foam fills the internal space of the mold and remains in it until the end of the polymerization and curing process, when the polymerization and curing process is completed, the mold is opened by lifting the lid and pushing the side walls of the mold. 9. The method according to p. 8, characterized in that the side walls of the mold are coated with a material that is not fixed to the polymerizable foam material, for example Teflon, Tarflen. 10. The method according to p. 8 or 9, characterized in that the opening of the mold is carried out by supplying compressed air of high pressure between the walls of the panel and the mold through channels formed in the walls of the mold. 11. The method according to p. 8 or 9, characterized in that the prepared panels can withstand at a temperature of 10-30 ° C for 2-30 hours. 12. The method specified in p. 10, characterized in that the prepared panels are incubated at a temperature of 10-30 ° C for 2-30 hours. 13. Heat-insulating composite facade panel, characterized in that it was prepared according to the method according to one of paragraphs. 8, 9, 12. 14. Heat-insulating composite facade panel, characterized in that it was prepared according to the method according to p. 10. 15. Heat-insulating composite facade panel, characterized in that it was prepared according to the method according to p. 11. 16. The use of a heat-insulating composite facade panel, which consists of a facade panel with a frame, preferably made of metal, which are irreversibly fixed to each other through the insulation layer, the insulation layer consists of foam, which, during foaming, irreversibly connects the facade panel to the frame, for simultaneous installation of the facade and thermal insulation of buildings, especially high-rise buildings, while the foam is a foam polystyrene polyurethane (PSUR), consisting of two plastics: rigid polyurethane foam (PUR) and expanded polystyrene (EPS).

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