RU2368737C2 - Gypsum-based perforated panel - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention is related to perforated panel on the basis of gypsum, to method of its manufacturing and method of its installation. Gypsum-based perforated panel with front and back sides and four side surfaces. Two side surfaces are arranged in the form of stepped rabbet, which is arranged so that in process of perforated panel installation with side arranged in the form of stepped rabbet in contact with the second perforated panel, identical distance is provided between openings. System is characterised with at least two perforated gypsum-based panels. Method for manufacturing of perforated panel is characterised. Methods for installation of perforated panel are characterised.

EFFECT: improved joint of panels.

17 cl, 12 dwg

Description

The invention relates to a perforated gypsum-based panel, a method for its manufacture and a method for laying it.

Gypsum-based perforated panels, in particular gypsum plasterboard perforated panels and perforated gypsum fiber panels, are used inter alia to improve room acoustics. They consist of one gypsum panel, with a large number of holes, which can have a different shape. Sound waves falling on it can pass through the holes, thus preventing the reflection of sound. Most often, sound-absorbing material, such as mineral wool or non-woven fabric, is attached to the rear side of the perforated panel to enhance the absorption effect.

Such panels are usually used as ceiling material, but can also be used as wall coverings.

Typically, to produce perforated panels, the gypsum plate is perforated, then the edges are trimmed to provide uniform dimensions. Deviations in the distance between the holes (perforations) when moving from one panel to another or deviations in the direction due to the non-parallel arrangement are clearly evident due to the regular arrangement (pattern) of the holes on the panel itself.

Basically, such perforated panels are mounted on a carrier, for example on a metal profile or on a wooden plank, and adjacent edges should be located at a certain distance from each other. To do this, it is necessary to control the distance between the panels to ensure a certain distance between the holes. Alignment in this case requires auxiliary devices, which are determined by the distance between the holes (depending on the type of holes) and are used in order to obtain the same distance between the holes in the transition region between the two panels. The goal in this case is to achieve a uniform appearance “without transition” throughout the entire surface.

The seam that occurs at the junction of the plates is closed with putty material, such as gypsum. The ceiling is then painted to eliminate the color difference and achieve a uniform and uniform appearance.

The disadvantage of this method is that for accurate alignment of the panels, at least two, and preferably three, people who must have experience in this matter are required, and, despite this, alignment is time consuming.

EP 1369215 A2 discloses one method for the production of drywall perforated panels that can withstand dimensional accuracy. The panels produced according to the method described there can be laid without joints, directly adjacent to each other, so that the seam will be the thickness of a hair.

Although this method achieves a fundamentally easier installation, its disadvantage is that due to the absence of suture areas, slight differences in the surface of the wall or ceiling, as well as differences in the height of the panels to be mounted, cannot be aligned. On top of this, small damage at the edges of the plates leads to the fact that in the area of thin joints there are wide irregular seams that must be repaired before the final painting.

Also, in the method described in EP 1369215 A2, if necessary, the seams can be subjected to a final treatment, for example, to remove protruding residues of the adhesive used to seal the residual seams.

US 2256761 discloses one joint reinforcer, for example of metal, into which a gypsum board with a stepped tongue can be inserted. In the future, when plastering the resulting wall from gypsum panels, the metal bracket will be hidden. Such solutions for perforated panels are unacceptable, as perforated panels usually do not plaster over the entire surface.

DE 20305974 represents one connection of end edges for laying gypsum plasterboards and gypsum plasterboard acoustic perforated panels in which the end side has a wave profile.

The presented invention aims to overcome the disadvantages of the existing level of technology.

This problem is solved using a perforated panel based on gypsum with one front, one rear side and four side surfaces, and at least two side surfaces are made in the form of a stepped tongue.

In one preferred embodiment, the at least two side surfaces are adjacent.

“Adjacent” means that the two side surfaces converge on the same corner of the panel.

“Seam” means a hole to be filled at least 2 mm wide. Embodiments in which the two edges of the panels are directly adjacent to each other and practically no seam should occur, will hereinafter be referred to as a seam with a thickness of hair.

"Step tongue" means that the side region is made in the form of a step. In this case, the step may have a different height or width accordingly. In addition, the edges of the panel should not be rectangular, but may be beveled (cut) or have a rounded shape. Rounded or chamfered edges in some areas may have a stepped tongue, and in another area may be without it. It is also possible that “visible seams” will remain on the front side that will not be puttied. At the visible seam, one part of the seam is sealed, while on the front side the seam remains.

It is also possible that the bevel may not extend along the entire length of the edge. There may also be areas in which the step tongue is made in whole or in part, i.e. stepped tongue is available only in certain areas of the side surfaces, and in other areas partially or completely absent.

In one embodiment, the perforated panel according to the invention has only two adjacent side surfaces in the form of a stepped tongue. When installing such panels, the installation is carried out in such a way that one perforated panel with a side surface in the form of a step tongue adjoins a side surface made without a step tongue so that a seam facing the room remains. Since with this installation method, the perforated panels are adjacent directly to one another, unlike standard technology, such installation is much easier, since it does not require adjustment or requires only a slight straightening depending on the pattern (location) of the holes. Skew is also eliminated, in which the perforated panels are no longer parallel to each other. The seam resulting from this can be filled in the usual way using filler or, respectively, filler material, for example building glue, acrylic material, dispersion or mineral-bonded materials or mixtures thereof, or, which is particularly preferred, gypsum-related material.

The following are other advantages of the invention. With the classic installation technology, the seams on the back side, that is, facing the wall and ceiling, are generally open, since the perforated panels are mounted on a wooden or metal frame. Therefore, the stacked filling material can exit almost unlimitedly on the back of the seam, so that the filling of the seam cannot occur under pressure. However, even a slight pressure promotes good adhesion of the filling material to the side surfaces of the perforated panel.

Due to the fact that according to the invention, the panels on the rear side are adjacent to each other or, respectively, have only a gap with a small width between them, the filler material can no longer protrude from the seam on the back side, so that the joint can be sealed more easily. Due to this, a significantly better lateral adhesion of the filling or, respectively, putty material and adhesive material is achieved.

On the other hand, since seams are subsequently sealed, minor damages at the edges (both on the front and rear sides) or differences in height between the panels to be mounted can be aligned as part of this seam seal.

In another embodiment, the perforated panels have a stepped tongue on all four side surfaces. In this embodiment, three stacking cases can be implemented.

In the first case, both stepped tongues are located on the rear side and are laid butt. The resulting seam is filled with filler material or may even remain open. In this case, it is necessary to pay attention to the fact that the width of the formed seam and thereby the size of the stepped tongue is chosen so that the finished wall or ceiling has the same distance between the holes and, accordingly, a uniform remaining visible seam is formed (seam pattern).

In one such case, installation is greatly simplified, as the alignment of the panels is carried out more easily.

In the second case, the panels can be installed in such a way that step dowels can alternate on the front and on the back side and thus enter into each other. In this case, almost seamless installation can be achieved, while the newly laid panel can advantageously be hooked onto an already installed panel using a step tongue so that the weight of the panel is partially transferred to the already installed panel.

In this case, the panels can be made in such a way that the opposite sides have longer sections of stepped dowels, alternating on the upper and lower sides. Alternatively, the longer sections of the step tongue may alternately lie on the same side, respectively, whereby the second panel is inserted with rotation to facilitate the entry of the panels into each other.

Such installation can be carried out as "dry" (that is, without glue and similar materials), and, as described, by gluing or correspondingly puttying.

In the third case, the stepped tongues are made on different side surfaces in different ways, so that, on the one hand, it is possible to insert into an already installed panel, and, on the other hand, there is still a seam, which can then be covered with filler material.

All embodiments of the invention, which include closing the seam with filler material, have the advantage that a slight difference in height between the panels to be mounted can be leveled and damage to the edges can be repaired during the work using filler or filler materials, such as building adhesive, acrylic putty, dispersion or mineral-bonded materials or mixtures thereof, and particularly preferably gypsum-bonded material, and possible displacement of holes could Aligned by minor refinement.

Perforated panels according to the invention can be obtained in a simple manner in which one panel is perforated and then cut during one operation. A stepped tongue can be obtained in various ways. In one embodiment, this is done by cutting twice, that is, first the entire panel is cut and then re-cut with a reduced depth to obtain a stepped tongue. In one pass, preliminary notching, cutting and tongue formation can be carried out. Alternatively, after the first cutting, milling can be applied to obtain a stepped tongue. In one preferred embodiment, a step tool can be used with which the cutting process can be carried out at two different heights. When installed at various depths, such a tool can be used both for cutting stepped dowels and for cutting even side surfaces.

The subject of the invention is also a system (“connection”) of panels according to the invention.

The invention is illustrated by the following drawings.

Figure 1 shows a schematic view of a perforated panel according to the invention, in which at least the shown side surface 3 is made as a stepped tongue. The step tongue may be symmetrical, as shown in figure 1.

Figures 2 and 3 show embodiments in which the side surfaces are made with different heights of the step tongue.

Figure 4 shows the side surfaces for which bevelling is performed in the area of the stepped tongue.

Figure 5 shows a laying view of perforated panels according to the invention. In this case, a panel with a stepped tongue adjoins the panel without a stepped tongue, while the panels in the region of the rear side 2 are joined seamlessly or respectively with only a slight seam (with hair thickness). The resulting seam on the front side (on the visible side) is then filled with filler material.

6 shows a variant in which the perforated panels are adjacent to each other, and in both joined areas there are stepped dowels which are joined to each other in the rear side region. The resulting seam is filled with filler material 4.

In another embodiment of FIG. 7, a step tongue is used to hook the panels together so that virtually no seam or only a seam of hair thickness is formed. This option does not realize all the advantages that other embodiments show.

In another embodiment, FIG. 8, it is shown how the benefits of mutual engagement with filling the seam can be used at the same time with correspondingly different forms of stepped tongues on the side surfaces.

Fig. 9 shows an embodiment of a perforated panel in which an edge is beveled in one separate area. This leads to the fact that the filler material is better adhesion in the resulting seam. On the other hand, the existing sections without bevels allow for easy adjustment of the panel.

10 shows an embodiment of perforated panels according to the invention, in which a step tongue is interrupted in separate areas. At the same time, the stepped tongue, as in previous versions, can be interrupted partially or completely. In this case, the interruption of the step tongue can be angular, inclined, etc. By means of the remaining areas of the step tongue, a more simplified alignment of the panels is achieved according to the invention. On one side surface in some embodiments, up to 90% of the step tongue can be reversed. The remaining 10% step tongue is sufficient to facilitate panel alignment.

11 shows a variant with reference to FIG. 7, in which a visible bevel remains on the front side, which is preferably not putty. Thus, when laying visible lines are obtained that are located at the same distance from each other.

12 shows an embodiment in which stepped tongues are made in opposing areas of the panel. This contributes to the engagement of the panels during their installation.

The panels according to the invention usually have dimensions of 200 × 120 cm. However, according to the invention it is also envisaged that the panels can be larger or smaller than this size. In particular, to perform the work of the master, panels of a slightly smaller size are especially recommended, since during operation they are easier to manipulate over the head.

Claims (17)

1. A perforated gypsum-based panel with front (1) and rear (2) sides and four side surfaces (3), and at least two side surfaces are made in the form of a stepped tongue, which is designed so that when laying perforated panel side, made in the form of a stepped tongue, in contact with the second perforated panel, the same distance between the holes. 2. The panel according to claim 1, characterized in that it is a gypsum board panel or gypsum fiber panel. 3. The panel according to claim 1 or 2, characterized in that at least two side surfaces are adjacent. 4. The panel according to claim 1, characterized in that at least one side surface at least on one edge is beveled. 5. The panel according to claim 4, characterized in that at least one side surface, made as a stepped tongue, is beveled. 6. The panel according to claim 1, characterized in that only two side surfaces are made in the form of a stepped tongue. 7. The panel according to claim 2, characterized in that only two side surfaces are made in the form of a stepped tongue. 8. The panel according to claim 3, characterized in that only two side surfaces are made in the form of a stepped tongue. 9. The panel according to claim 1, characterized in that the four side surfaces are made in the form of a stepped tongue. 10. The panel according to claim 1, characterized in that the step tongue is completely or partially interrupted. 11. A system with at least two perforated gypsum-based panels according to claim 1, wherein the first perforated gypsum-based panel with its side as a step sheet pile is in contact with the second perforated gypsum-based panel, and the seam between them is closed filling material. 12. The system according to claim 11, characterized in that the filler material is a filler and filler material, for example building glue, acrylic material, dispersion or mineral-bonded material, or a mixture thereof, or, which is particularly preferred, gypsum-related material. 13. A system with at least two perforated gypsum-based panels according to claim 1, wherein the first perforated gypsum-based panel with its side as a step sheet pile is in contact with the second perforated gypsum-based panel with the same shape as a step sheet pile side, so that there is no seam left, or there is a seam the thickness of a hair, or a visible seam. 14. A method of manufacturing perforated gypsum-based panels according to claim 1 with the following steps:
perforating the gypsum panel to obtain a perforated gypsum panel;
the implementation of cutting along the side surface, and at least two adjacent side surfaces are in the form of a stepped tongue. 15. The method of laying the perforated gypsum-based panels according to claim 1, wherein the perforated gypsum-based panel made in the form of a step sheet pile is brought into contact with another perforated gypsum-based panel so that a seam is formed that is closed with filler material. 16. The method of laying perforated gypsum-based panels according to claim 1, wherein one perforated gypsum-based panel made in the form of a step tongue and groove is brought into contact with another perforated gypsum-based panel with a side also made in the form of a stepped tongue so that there is no seam. 17. The method of laying perforated gypsum-based panels according to claim 5, wherein one perforated gypsum-based panel made in the form of a step tongue and groove is brought into contact with another perforated gypsum-based panel with a side also made in the form of a step tongue, at least one step tongue is beveled so that a visible seam remains.

Images