A Wall Panel Embodiment Technical Field

The invention relates to wall panels used in the construction sector.

The invention particularly relates to a monolithic wall panel used in building construction for separating spaces as interior and exterior spaces, and to the production method of this panel.

State of the Art

Wall panels are walls in the form of panels made of coating materials of various characteristics to be used instead of concrete, tiles, bricks, pumice concrete, and gas concrete etc. materials.

The workmanship and costs of the prior art conventional structure materials are high. When said structure materials are used, extra work load is required (such as plastering), and this also increases the costs. Moreover, with the materials used in the known status of the art, the materials are required to be thick in order to provide heat insulation. And the material with increased thickness adds to the weight of the building structure. In these kinds of applications, the framework costs of buildings are increased.

In the literature, on of the patents about this subject is the patent application No. US2013326982. The sandwich panel of the invention relates to a wall panel, which does not have a composite structure, and comprises two layers of concrete with insulation feature. The application also discloses the production method of said panel.

On the other hand, the application No. TR201005343 relates to ready-made plates/panels with paper cell structures. However, said panels are flammable due to the paper cells they comprise. Moreover, said paper cells also cause problems related to plumbing. It is a light material; but it is not quite suitable for use as a structure material due to said characteristics.

As a result, the above said drawbacks and the inadequacy of the prior solutions about the subject have necessitated improvement in the related technical field.

Purpose of the Invention

The present invention relates to a wall panel embodiment, which meets the above said requirements, eliminates all of the drawbacks and brings about some additional advantages.

The primary purpose of the invention is to obtain light, easily-mounted, and economical ready-made wall panels to be used as interior space separators and exterior construction materials in buildings.

A purpose of the invention is to provide wall panels that are ready for assembly and have sound and heat insulation features. Due to heat insulation; the cooled or heated living space is maintained at constant temperature. Besides; cold air or hot air is prevented from entering into indoor spaces. Moreover, noise pollution is prevented from reaching living spaces due to the sound insulation characteristics.

Another purpose of the invention is to apply lower load on the framework due to the lightness of the panel. Since the m ² weight of the wall panels according to the present invention are 20-25 kg, they do not cause problems for the building structure in terms of weight. Besides, the costs are reduced as a result of using lower amount of reinforcements or steel.

A similar purpose of the invention is to provide easy assembly due to the lightness of the ready-made wall panel. Moreover, it reduces the risks during earthquakes due to the lower amount of loads applied on the building construction. Another purpose of the invention is to ensure strong adhesion by means of the adhesive (1 10) found within the panel. In this way, it becomes stable and durable against external impacts. A similar purpose of the invention is to reduce the time and cost requirements, since it does not require plastering on the ready-made wall panel.

The purpose of the invention is to obtain wall panels, to which electrical and mechanical installations can easily be installed.

Another purpose of the invention is to provide ready-made wall panels made of recyclable materials.

In order to achieve the above said purposes, the invention is a wall panel to be used as a space separator in indoor spaces and a structure material in outdoor spaces. Said wall panel, respectively comprises an exterior layer, an adhesive, a sealant layer, an adhesive, and an interior layer.

In order to achieve the purposes of the invention, said wall panel production method comprises the below given operation steps:

• preparing an adhesive,

• application of the prepared adhesive onto the interior surface of the exterior layer or the interior layer,

• placement of the sealant layer on top of the applied adhesive,

· application of adhesive on the placed sealant layer, and

• placement of the exterior layer or the interior layer as a final layer onto the adhesive-applied sealant layer.

The structural and characteristic features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations. Figures for Better Understanding of the Invention

Figure-1 , is a general sectional view of the wall panel embodiment.

Figure-2, is a sectional view of the wall panel embodiment used in exterior spaces. Figure-3, is a sectional view of the wall panel embodiment used in interior spaces. Figure-4, is an alternative sectional view of the wall panel embodiment used in interior spaces.

Figure-5, is a sectional view of the combined state of wall panels.

Figure-6, is a sectional view showing the connection detail of two wall panels.

Drawings do not have to be scaled and details not necessary for understanding the present invention may be neglected. Moreover, components which are at least widely equal or which have at least widely equal functions are shown with the same number.

Reference Numbers

10. Wall panel

20. Exterior layer

21 . Fibercement plate

22. Plasterboard panel

30. Sealant layer

40. Interior layer

50. Post

60. Beam

70. Floor

80. Connection Space

90. Net

100. Joint

1 10. Adhesive

120. Polyurethane foam

130. Alignment sheet Detailed Description of the Invention

In this detailed description, the preferred embodiments of the interior and exterior wall panel (10), which is the subject of the invention, will only be disclosed for better understanding of the subject, and will not form any limiting effect.

The invention is a wall panel (10) embodiment to be used in interior and exterior spaces and formed of a total of three layers, which are: an exterior layer (20), a sealant layer (30), and an interior layer (40). Figure-1 is a general sectional view of the wall panel (10) embodiment. An adhesive (1 10) is used among the layers in order to combine said panels (10).

Figure-2 is a sectional view of the wall panel (10) embodiment used in exterior spaces. The external wall panel (10) respectively comprises the below given layers:

• a fibercement plate (21 ) as an exterior layer (20),

· an adhesive (1 10),

• polystyrene as a sealant layer (30),

• an adhesive (1 10), and

• a plasterboard panel (22) as an interior layer (40). By means of the fibercement plate (21 ) that is used as an exterior layer (20), the wall panel (10) used in outdoor spaces has durability, water/vapour impermeability, and elasticity characteristics.

Figure-3 is a sectional view of the wall panel (10) embodiment used in interior spaces. The interior wall panel (10) respectively comprises the below given layers:

• a plasterboard panel (22) as an exterior layer (20),

• an adhesive (1 10),

• polystyrene as a sealant layer (30),

• an adhesive (1 10), and

· a plasterboard panel (22) as an interior layer (40). The polystyrene (EPS) material used as a sealant layer (30) between the interior and the exterior panels (10) provides composite adhesion such that no air bubble is left between the layers with the contribution of the adhesive (1 10). The density of said polystyrene (EPS) material is between 15-21 . Moreover, it can be 10, 15, 20 cm according to the thickness of the EPS wall used.

The plasterboard panels (22) both used in the interior and the exterior panels (10) have antibacterial and antistatic characteristics due to their plaster feature. Moreover, the plasterboard panels (22) used as interior layers (40) are fire-resistant.

An adhesive (1 10) is used for combining the layers of the panel (10) according to the invention used in interior and exterior spaces. The adhesive (1 10), which is the most important material for the panels (10), is required to be prepared between +5-30 ^< C. Said adhesive (1 10) is formed of a combination of two components called as A and B. For the formation of the adhesive (1 10), component A is solvent-free polyurethane comprising barite as filling material; and component B comprises polymeric MDI and isocyanate. In the adhesive (1 10) formed, the general ratio of A:B is 1 :0.15. In the invention, 4 kg of said component A and 0.6 kg of component B are used. Afterwards, components A and B are mixed in a container for 3-5 minutes at 200-300 rpm. During use of the adhesive (1 10), the adhesive (1 10) should be applied to the surface within 20 minutes following its preparation. The adhesive (1 10) solidifies within said 20 minutes. Therefore, ensuring its contact with the surfaces within 20 minutes is an important factor. Following application of said adhesive (1 10) and its solidification, it can be used between -40 to +50 ^< C . It does not go through any chemical or physical change within said temperature range.

During production of the panels (10); first of all, the adhesive (1 10) prepared as described above is applied onto the interior surfaces of the interior layer (40) or the exterior layer (20) within 20 minutes of its preparation via cylinders. The sealant layer (30) EPS is then adhered on the adhesive (1 10) after being cut in accordance with the thickness of the wall to be formed. Also, polyurethane adhesive (1 10) is applied onto the exterior surface of the sealant layer (30). Finally, the exterior layer (20) or the interior layer (40) is placed onto the applied adhesive (1 10). The wall panel (10) formed by combination of the layers via an adhesive (1 10) is compressed by using a press. The panels (10) are kept under the press under a surface pressure of 6-8 tons / 3.6 m ² for 3-4 hours. Afterwards, the panels (10) taken out of the press are kept idle for 24 hours for complete drying. During application of said method, the ambient temperature is required to be between +10-40 ^< C. The optimum temperature is 25 ^< C. Following the reaction (after solidification and adhering the layers), said adhesive (1 10) does not go through any expansion between -18°C and +55°C. No dilation or softening is observed on the wall panel (10) that is brought to the final state by means of application of adhesive (1 10) between the layers and pressing. Moreover, it does not get affected from the weather conditions. In this way, the production of the panel (10) would be completed.

The critical points to be considered during production of the panel (10) are as follows:

- The environment should be dry and moisture-free and the temperature should be between +10-40 .

- Careful consideration should be given to the ratio, mixing speed, and the time period during preparation of the adhesive (1 10) and the predetermined 20 minutes shouldn't be exceeded following preparation (and before application) of the adhesive (1 10).

- The pressure should not exceed 6-8 tons.

- Adhesive (1 10) shouldn't be used excessively. If used excessively, it would cause spill over due to the pressure applied by the press.

- The panels (10) shouldn't be broken or fractured. Otherwise homogeneity would be affected with the impact of the press.

- The components A and B forming the adhesive (1 10) should be between +15- 40 . The shelf lives of the components are determi ned as 6 months. The materials not used for 6 months after their date of production should be discarded.

The wall panels (10) according to the present invention are connected to each other with an interlocking system. While one of the edges of the wall panel (10) forms a female structure, the other edge has a male structure. While the wall panels (10) are combined with each other, the female structure is combined with the male structure as an interlocking system. Finished wall panels (10) are found in a state that they are interlocked with each other such that a connection space (80) would be left between two panels (10). Joints (100) are opened on the connection space (80) that is left between two panels (10), through the outermost layer, in an externally accessible manner. Afterwards, polyurethane foam (120) injection is made through the joints (100) opened. Said polyurethane foam (120) preferably has a density of 30. The polyurethane foam (120) applied expands to 6-8 times more of its original volume between the two panels (10). In this way, the connection spaces (80) are filled with polyurethane foam (120) filling. As a result, connection between the panels (10) and posts (50), beams (60), and floor (70) etc. structural components would be ensured. Figures 5 and 6 provide a sectional view of the combined state of the wall panels (10). This system is used in buildings in mounting wooden door cases and also in aluminum joineries. Afterwards, nets (90) are drawn at the wall panel (10) connection points, and covered with plaster cast in order to obtain a smooth surface. The mounting of said wall panels (10) with each other should be made between +15-40 ^< C due to the polyurethane foam (120) used.

In an alternative embodiment of the invention, an alignment sheet (130) is used in order to provide correct alignment when panels (10) are placed, and prevent panels (10) from sliding to undesired excessive spaces that are formed during mounting. Thanks to the alignment sheet (130) used, the panel (10) does not slide away due to the space formed. Standard alignment sheets (130) are galvanized and formed in "L"-shape; and attached to concrete or steel. The dimensions of said alignment sheet (130) are 30x50x1 .5 mm. The 50 mm part is to be retained within the wall. Figure-4 is an alternative sectional view of a wall panel (10) embodiment used in interior spaces. In this alternative structure, two of the interior space wall panels (10) are used.

The wall panels (10) of the invention can be chosen according to the characteristics of the spaces and can be used on walls and as flooring materials on steel construction grid systems.