Technical Field The invention is related to a composite panel containing clay-based exterior coating and glass fibre reinforced concrete used for sound and thermal insulation in buildings and a production method in connection thereunto.

Prior Art

In order to provide sound and thermal insulation on the exterior facades of buildings, sheathing application is performed or insulating hollow bricks containing insulation material are used. In the exterior sheathing method, the insulation materials are attached to the exterior of the building with dowels and/or by bonding. There are reinforcement mesh and exterior sheathing lining for better adhesion of the plaster on the heat insulation material in the exterior cladding. After performing these stages, sound and thermal insulation of the building is ensured. These kinds of insulation techniques on building exterior take a lot of time and bring a material burden.

An exterior facade coating material similar to a brick, which contains an insulating layer, is mentioned in the national utility model document with the number TR2016/11045 available in the prior art. High density mineral wool is used as the insulation layer in said document. It comprises a brick-like plate and an insulating layer bonded and/or fixed to each other. Tongue-and-groove joint ends are available. This product is only applicable to columns and beams. In the prior art, glass fibre reinforced concrete panels are also used as the exterior coating material. However, the glass fibre reinforced concrete panels in prior art are composed of a single layer. Therefore, no effective insulation can be achieved.

Purpose of the Invention

The purpose of the invention is to create a composite panel, which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones.

Another purpose of the invention is to obtain a composite panel that is resistant to abrasion and decay.

Another purpose of the invention is to obtain a composite panel having the same dimensions and the same strength at all sides with the use of fibreglass mesh. Another purpose of the invention is to obtain a composite panel that allows to obtain more aesthetic and different architectural views.

The composite panel featuring a clay-based exterior cladding material developed to achieve said objectives; has a glass fibre reinforced concrete layer and a clay-based layer obtained from terra-cotta based soil. The invention is an exterior cladding material with an integrated structure.

The production method related to the composite panel featuring a clay- based exterior cladding material developed for carrying out said objectives comprises following process steps; primarily laying the clay-based layer (2) obtained from terra-cotta based soil into the designated mould (4) made of silicone rubber material, pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil,

laying the glass fibre mesh on concrete mortar (3.1),

pouring concrete mortar (3.1) on the mesh laid,

leaving poured concrete mortars (3.1) to dry,

removing the moulds (4) it dries.

Description of Figures

Attached Figure - 1 is the perspective view of exploded state of the layers of the composite panel (1).

Attached Figure -2 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).

Attached Figure-3 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).

Attached Figure-4 is the rear view of the processes step concerning laying the glass fibre mesh (3.2) on the concrete mortar (3.1).

Attached Figure-5 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the glass fibre mesh (3.2).

Attached Figure-6 is the front view of the composite panel (1) when the silicone mould (4) is removed.

Attached Figure-7 is the rear view of the processes step concerning laying the clay-based layer (2) on the silicone mould (4).

Attached Figure-8 is the rear view of the processes step concerning pouring concrete mortar (3.1) on the clay-based layer (2).

Attached Figure-9 is in an alternative application of invention, the rear view of the processes step spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1). Attached Figure- 10 is in an alternative application of invention, the rear view of the processes step pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed.

Attached Figure- 11 is the front view of the composite panel (1) when the silicone mould (4) is removed.

Numbers and names of main parts mentioned in the figures are given below.

(1) Composite panel

(2) Clay-based layer

(3) Glass fibre mesh reinforced concrete layer

(3.1) Concrete mortar

(3.2) Mesh

(4) Mould

Detailed Explanation of the Invention

The invention is related to an exterior cladding material in composite structure, wherein one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil and the production method in connection thereunto. As the insulating layer, glass fibre mesh reinforced concrete layer (3) which has outstanding fire resistance compared to mineral wools, a high acoustic value and is lighter and more natural compared to mechanical stones, is preferred.

Glass fibre mesh reinforced concrete layer (3) offers maximum resistance to external factors thanks to its high cement content and low permeability. The composite panel (1) featuring such glass fibre mesh reinforced concrete layer (3) is obtained by pouring the concrete mortar (3.1) into the joints clearances and on to the back surface of the coating brick, laying the glass fibre mesh (3.2) onto it and finally pouring concrete mortar (3.1) and leaving for drying.

In an alternative embodiment of the invention; the composite panel (1) can also be obtained by mixing the glass fibre with the concrete mortar (3.1) with low water ratio and then leaving for drying. In another alternative embodiment of the invention, the glass-fibre mesh reinforced concrete layer (3) in mortar form may be poured by using a spraying system. It can be used in various moulding processes as it has pouring is possible with the spraying system. Steel building materials can be used in glass fibre reinforced concrete layer (3), if desired and required. Thus, a more robust structure is obtained.

The clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material, then the fibre- free concrete mortar (3.1) is poured into the joint clearances and on the rear surface of the clay-based layer (2). On top of that, glass fibre mesh (3.2) is laid as a cover. The concrete mortar (3.1) is poured again after the laying process is completed. The composite panel (1) prepared after the last treatment is left for one day to dry and when it is dry, silicone rubber moulds (4) are removed. Moulding can be performed according to the desired size and design. As a result, the glass- fibre mesh reinforced concrete layer (3) and the clay-based layer (2) become a composite structure.

Concrete mortar (3.1) used in the invention contains cement, plasticizer, silica sand and acrylic polymers. The thickness of said concrete mortar (3.1) can vary between 2-12 mm.

Impact and crack formation in the composite panel (1) is prevented thanks to the glass-fibre mesh (3.2) used in the invention. Furthermore, the alkali resistance of said composite panel (1) is increased. In addition, the composite panel (1) is provided with high tensile strength. An almost homogenized layer is obtained by means of the glass fibre mesh (3.2). In this way, each zone of the glass-fibre mesh reinforced concrete layer (3) has the same strength.

The invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which is composed of following process steps; the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), laying the glass fibre mesh (3.2) on concrete mortar (3.1) (1003), pouring concrete mortar (3.1) on the mesh laid (3.2) (1004),

leaving poured concrete mortars (3.1) to dry,

removing the moulds (4) it dries (1005).

In an alternative embodiment of the invention, glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen. The invention is related to the production method of the composite panel (1) containing clay-based exterior coating used for sound and thermal insulation in buildings, which comprises following process steps;

the clay-based layer (2) obtained from terra-cotta based soil is primarily laid into the designated mould (4) made of silicone rubber material (1001), pouring concrete mortar (3.1) into joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil (1002), spraying the glass fibre mesh reinforced concrete material on the concrete mortar (3.1) (1003a),

pouring the concrete mortar (3.1) on the glass fibre mesh reinforced concrete material sprayed (1004a),

leaving poured concrete mortars (3.1) to dry,

removing the moulds (4) it dries (1005). The clay-based layer (2) obtained from terra-cotta based soil is embedded into glass fibre mesh reinforced concrete layer (3) at the level that is intended to be seen from the top. In an alternative embodiment of the invention, glass fibre mesh reinforced concrete material is sprayed on the clay-based layer (2) obtained from terra-cotta based soil, at the level desired to be seen. In addition, when brick or stone products are used in exterior cladding, the clearance between the stones or bricks is filled with concrete mortar (3.1) as an additional process. Since the clearance is filled with the glass fibre mesh reinforced concrete layer (3) in the composite panel (1) production, no additional process is needed.

The composite panel (1), which consists of the combination of the clay- based layer (2) obtained from terra-cotta based soil and the glass fibre mesh reinforced concrete layer (3), is more effective compared to glass fibre reinforced concrete panels that are composed of a single layer, in terms of both acoustic sound insulation and strength.

The clay-based layer (2) used in the glass fibre mesh reinforced concrete layer (3) can be produced in any desired design and size. Also, the dimensions of the composite panel (1) may vary depending on the request and the requirements. In an alternative embodiment of the invention, composite panels (1) produced in large dimensions are supported by steel. In another alternative embodiment of the invention, the mesh is made with steel or different metals into the glass fibre mesh reinforced concrete layer (3). In this way, the composite panels (1) are not dispersed when exposed to an external impact and the damage caused is reduced.

The invention is related to an exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having one surface is composed of glass fibre mesh reinforced concrete layer (3) as the insulating layer and the other surface is composed of a clay-based layer (2) that is obtained from terra-cotta based soil. The invention is related to a composite panel (1) featuring a clay-based exterior cladding material used for sound and thermal insulation in buildings, which is characterized as having a clay-based layer (2) obtained from terra-cotta based soil laid into a silicone rubber mould (4), concrete mortar (3.1) poured into the joint clearances and on the back side of the clay-based layer (2) obtained from terra-cotta based soil, a glass fibre mesh (3.2) laid on the concrete mortar (3.1) and concrete mortar (3.1) poured on the mesh (3.2) laid, the concrete mortar (3.1) featuring cement, plasticizer, silica sand and acrylic polymers and the glass fibre mesh reinforced layer (3) featuring a mesh made of steel or different metals.