System panels for microcement installation

Abstract

Prefabricated panel system with a multi-layered carrier panel comprising at least one core of extruded polystyrene (e.g. Wedi), wood-based materials (e.g. OSB), gypsum fiberboard, hemp fiber lightweight elements or combinations thereof, wherein the carrier panel is coated on at least one side with a microcement layer.

Description

[0001] The invention relates to a modular panel system for the efficient production of microcement surfaces on floors, walls, and furniture. The aim is to significantly simplify and accelerate the processing of microcement by means of prefabricated support elements with optimized butt joints. 1. Structure and materials

[0002] The panels are preferably made of lightweight, dimensionally stable materials with high tensile bond strength for microcement, in particular cement-bonded lightweight panels, glass fiber reinforced plastic (GFRP), high-pressure laminate (HPL), XPS or gypsum fiber composite panels, as well as bio-based carrier materials such as hemp or flax fibers. The panels are reinforced on both sides with fabric and have a thickness between 4 and 10 mm. Edge reinforcement, e.g., by a laminated aluminum profile, can be provided as an option. 2. Bath relocation with defined SMoß system

[0003] The panels can be bonded directly to level substrates (e.g., leveled screed or cementitious leveling compound) using a suitable adhesive (e.g., flexible or reactive adhesive). A three-stage structure is provided at the joints: (1) tongue-and-groove connection for height adjustment, (2) recessed adhesive joint for fiberglass mesh, (3) overlying cover layer for the final microcement layer. A factory-applied adhesive strip protects the joints during removal. After drying, the surface can be sanded and sealed. The resulting surface is virtually seamless and ready for immediate use.

[0004] The panels are laid modularly using a specially developed butt joint system consisting of three staggered levels: 1. A deep tongue and groove connection along the longitudinal sides of the panels, which ensures a precise fit, height control and mechanical stability during installation. 2. A recessed, factory-installed adhesive joint above the tile, into which a strip of fabric (e.g., fiberglass or basalt fabric) is inserted and embedded with a cementitious adhesive. This joint is typically 10–15 cm wide (5–7.5 cm per tile) and allows for stress-free bridging of the tile joints. 3. A top layer with a factory-ground transition edge, protected with adhesive tape. After the lower adhesive joint has dried, the final coat of microcement (approx. 1-1.5 mm thick) is applied over the transition zone and then sanded flush with the rest of the panel surface. The protective tape prevents material overlap and is removed after completion, leaving no visible joints or height differences.

[0005] The entire construction enables fast, virtually seamless installation of large-area microcement elements through a clearly defined, repeatable system with minimal sanding and filling effort. 3. Summary

[0006] The invention describes an industrially prefabricated system for laying microcement surfaces with minimal troweling effort, defined butt joints, optional edge profiles, and compatible fabric integration for a seamless transition finish. The modular application allows for the efficient, cost-effective, and reproducible installation of microcement surfaces in large-scale applications. 4. Typical formats and areas of application

[0007] The panels are available in various standard sizes to cover both large-scale applications and smaller modular areas. Typical formats for floor and wall installation are: -250cm×125cm -200cm×100cm -120cm×60cm

[0008] Smaller cuts (e.g., 60 cm × 60 cm or 120 cm × 40 cm) are also available for furniture, kitchen, and small-area applications. The panel thickness ranges from 4 to 10 mm, depending on the application. Thanks to the modular joint system, even large areas can be covered with virtually invisible seams. The panels are transported flat, can be cut to size on-site, and are easily glued to flat surfaces.

Claims

[1] Prefabricated panel system with a multilayer carrier panel comprising at least one core of extruded polystyrene (e.g. Wedi), wood-based materials (e.g. OSB), gypsum fiberboard, hemp fiber lightweight elements or combinations thereof, wherein the carrier panel is coated on at least one side with a microcement layer. [2] Panel system according to claim 1, wherein the carrier panel is designed as a sandwich structure with a centrally arranged OSB core and Wedi or rigid foam panels on both sides. [3] Plate system according to one of the preceding claims, wherein cross braces or hollow chambers are provided within the support plate to influence the bending behavior and the optical solidity. [4] Panel system according to one of the preceding claims, wherein the visible edges are framed with aluminium or similar profiles, in particular with prefabricated corner modules or mechanically reinforced connectors. [5] Panel system according to claim 4, wherein the edge protection profiles have a structured adhesive surface and / or a groove for receiving fiberglass fabric. [6] Panel system according to one of the preceding claims, wherein the connection of several panels is effected by fiberglass reinforcing strips which are laid over joints as in drywall construction and are covered several times with flexible adhesive. [7] Panel system according to one of the preceding claims, wherein the microcement layer is applied mechanically, in particular robotically, and thereby produces a structured or smooth surface. [8] Panel system according to one of the preceding claims, wherein the top and edges are coated with microcement and the underside is only filled with flexible adhesive for cost reasons. [9] Plate system according to one of the preceding claims, wherein, in addition to the carrier plate, internal reinforcing elements, in particular aluminium profiles, grids or struts, are integrated. [10] Panel system according to one of the preceding claims, wherein the surface is finally sealed with a transparent protective layer based on polyurethane, epoxy resin or bio-based materials. [11] Panel system according to one of the preceding claims, which is manufactured in industrial series production by means of CNC cutting, automated profile bonding and robot-assisted microcement coating. [12] Panel system according to one of the preceding claims, manufactured in standard dimensions or as a custom-made product, in particular in lengths up to 6 m and widths up to 90 cm, suitable for use as a kitchen worktop, washbasin top, wall cladding or furniture module. [13] Panel system according to one of the preceding claims, wherein both the top, the edges and the bottom are completely coated with microcement, particularly in freestanding applications or in the case of visible undersides. [14] Panel system according to one of the preceding claims, wherein the carrier panel consists of a completely natural or recyclable material, in particular pressed hemp shives, hemp fiber mats, flax shives, chopped straw or combinations of these natural materials, bound with plant or mineral binders such as clay, lime, starch or magnesium cement, and wherein the fabric used for surface reinforcement consists of hemp fibers or other plant-based fibers, in particular as a fabric roll analogous to fiberglass reinforcing fabric, embedded in flexible adhesive and plastered several times. [15] Panel system according to one of the preceding claims, wherein mounting structures are provided within the carrier panel, along the edges or on the underside of the panel, in particular threaded inserts, press-fit sleeves, embedded magnetic holders, snap-in modules, recessed transverse anchors, or alternatively attached mounting elements such as screwable mounting strips, which enable the subsequent attachment of the panel to substructures or modular kitchen systems such as JOLLYCORE, wherein the positioning is either fixed (e.g. in grid intervals) or flexibly adjustable. [16] Panel system according to one of the preceding claims, wherein factory-prepared adapter strips, mounting rails or structured mounting slats are attached to the underside or back of the panel, which enable variable screwing, hanging or magnetic mounting to different support systems, wherein these modules are interchangeable or retrofittable and can be integrated into standardized kitchen systems or special solutions.