Shower floor element and method for its manufacture

Description

[0001] The invention generally relates to a shower floor element and a method for its production.

[0002] To meet specific thermal and / or sound insulation requirements, shower floor elements must have appropriate insulating properties. For this purpose, such shower floor elements often feature an insulating panel made of rigid foam.

[0003] The shower floor elements currently in use are often designed as composite panels and feature a core, usually made of extruded polystyrene, covered on both sides by a stiffening layer that protects the foam from damage and serves as an adhesive base for the component's top layer. Extruded polystyrene has a high density and compressive strength and a homogeneous structure.

[0004] Rigid foam made of expanded polystyrene, on the other hand, is characterized by its coarse-grained structure. Due to its very low thermal conductivity, expanded polystyrene is used as a single-layer board for thermal and impact sound insulation. As a composite board, it is sometimes attached as a single-sided layer to rigid boards, such as plasterboard.

[0005] For example, DE 20 2005 018684 U1 discloses a support structure for a shower floor element made of expanded polystyrene particle foam. A bonding layer is applied directly to the support structure. The bulk density of the support structure is at least 60 kg / m³, so that the vertical forces exerted on the sanitary surface during intended use do not impair the bonding.

[0006] Both of these rigid foam materials have a low density and a closed-cell structure. They are resistant to water and moisture. The latter is particularly true for extruded polystyrene due to its uniform structure.

[0007] Furthermore, JP H09 124828 A discloses a foamed material for the production of labels, into which lettering can be incorporated by surface treatment. o. ä. can be introduced.

[0008] The disadvantage of conventional shower floor elements is their poor energy performance due to energy-intensive production, limited recycling, and complex disposal and recycling. Furthermore, the sealing element required on the top, in combination with polystyrene as a supporting element, causes the composite panel to warp over time from production to installation and possibly break during installation. To prevent warping, thicker supporting elements are used, which must also have a counter-tension element on the back.

[0009] There is therefore a need for shower floor elements that can be used as floor elements for shower areas and that have the necessary flatness and low thickness to be used in particular for shower areas with a low height structure, so that these can also be designed flush with the floor.

[0010] To achieve the object, a shower floor element according to claim 1 and a method for producing a shower floor element according to claim 12 are specified. Claims which refer back to claims 1 and 12 represent advantageous embodiments.

[0011] Typically, such shower floor elements comprise a supporting element and a cover element with a sealing element in between.

[0012] According to the invention, the supporting element is made of a rigid foam board made of polyethylene terephthalate. The rigid foam board has a sealing element for creating a waterproof layer.

[0013] A rigid foam board made of polyethylene terephthalate means that the rigid foam board consists essentially of polyethylene terephthalate. This means that in addition to polyethylene terephthalate, non-mechanically acting additives such as z. B. It may contain color pigments, fire retardants, antifungal agents, etc. Rigid foam is a foamed material or foam that offers such high resistance to deformation under compressive load that it can be used as a construction material.

[0014] The main advantages of a rigid foam board made of polyethylene terephthalate are excellent mechanical properties and low weight.

[0015] Polyethylene terephthalate rigid foam boards have demonstrated long-term structural and dimensional stability in long-term fatigue tests, which is particularly desirable for construction products. The long-term stability of the insulating properties and the associated reliable insulation performance, as well as the moisture-resistant, closed-cell, and homogeneous structure, are properties that are desirable in rooms where moderate to high levels of moisture are expected. In addition, they are resistant to solvents, acids, salts, and other substances. The homogeneous surface also allows for a smooth and glossy coating, which can also be used as a finished surface and is easy to clean.

[0016] Furthermore, the rigid foam board is compatible with numerous different production methods and coating systems, allowing for customized material combinations. This property advantageously supports the combination of the rigid foam board with the professional waterproofing required in damp rooms. The surface quality and extensive material compatibility allow the rigid foam board to be combined with a sealing element to create a waterproof layer. z. B. For use in damp rooms. Optionally, a sealing element can also function as a protective layer.

[0017] The use of polyethylene terephthalate is advantageous in terms of both the energy balance and the sustainability of the product if the rigid foam board is made of recycled polyethylene terephthalate according to one embodiment of the invention. Polyethylene terephthalate is used primarily for the production of drinking bottles and a wide variety of food wraps, which are disposed of after use and increasingly recycled. This provides a raw material with a good energy balance that, with appropriate production-related measures, allows for climate-neutral production of polyethylene terephthalate and is itself recyclable.

[0018] According to the invention, the sealing element and the rigid foam board are bonded together. Preferably, they are bonded together over their entire surface.

[0019] This increases stability and ensures the most uniform mechanical connection possible between the composite panel or rigid foam panel and the sealing element, so that z.B. Tensile stresses do not lead to cracking and high long-term stability can be achieved.

[0020] The sealing element and the rigid foam board can preferably be bonded together with a silane-based polymer adhesive. Such an adhesive can z. B. contain silane-modified polyether-based polymers that crosslink with atmospheric moisture or additives, thereby forming a strong adhesive bond.

[0021] The advantages of such adhesives, also known as MS adhesives, are the formation of permanently elastic bonds that can withstand, for example, frequently repeated movements without the bond being compromised by cracks, tears, and / or detachments. Furthermore, these adhesives are essentially free of harmful substances. d. h. For example, they do not contain solvents or isocyanates and can therefore be processed easily and safely.

[0022] According to further embodiments of the invention, the rigid foam board can have a protective layer on at least one side, optionally on both opposite surfaces, or on all sides of the foam. For example, flow layers can be used as protective layers, which can optionally contain reinforcing fibers. Mineral coatings and other protective layers can also be used as protective layers, as explained below. For example, a sealing element can also function as a protective layer.

[0023] The inventive use of polyethylene terephthalate as the rigid foam panel of the shower floor element, in conjunction with the permanently elastic bonding using a silane-based polymer adhesive, makes it possible to dispense with the counter-tension element known from the prior art on the underside of the rigid foam panel. If a protective layer is arranged there to prevent damage to the rigid foam panels, which are sometimes only a few centimeters thick, for example, 2 or 3 cm, protective layers with a thickness of 0.3 mm and less, preferably less than or equal to 0.2 mm, are sufficient. .Such protective layers serve, for example, to protect the material during handling during manufacturing, transport, storage, sale, or installation. If damage can be prevented by other means, such as suitable mounting, storage methods, packaging, temporary protective measures, for example, on the sides of the rigid foam board, or other measures, a protective layer can be completely dispensed with, at least on the back.

[0024] Compared to the state of the art, the energy balance of the shower floor element is further improved, even with the formation of a protective layer on the back. The rigid foam board is lighter and thinner. Furthermore, less material is required for a shower floor element. To improve the energy balance of the shower floor element according to the invention, the material used also allows the use of a CO2-reduced mortar. z. B. Earth Friendly Mortar, or concrete for making a shower floor.

[0025] According to further embodiments of the invention, the sealing element can be designed in various ways. For example, it can be film-like or fleece-like.

[0026] Films are generally considered to be homogeneous flat structures made of a thin material that meets the relevant requirements, in this case permanent and, if necessary, crack-bridging watertightness.

[0027] Nonwoven sealing elements are sheet-like structures made of natural or synthetic fibers, arranged in either an aligned or random pattern. The spun fibers or filaments are glued, welded, sewn, or needled together. Compared to film-like sealing elements, they exhibit greater extensibility and are also watertight.

[0028] Depending on the size of the building board, both variants can be implemented, for example, by arranging sealing membranes that are connected to each other in a watertight manner. Alternatively, a film-like or fleece-like sealing element can be applied over the entire surface. A combination with a coating, for example, using a hardening sealant, is also possible.

[0029] The sealing element can be formed alternatively or in combination on at least one surface of the rigid foam board and / or as a layer within the rigid foam board. A sealing layer within the composite board represents a further layer in the composite and can also be designed and constructed as described above. Alternatively, a coating is also possible in such an embodiment.

[0030] Furthermore, the adhesive improves the watertightness of the shower area created with the shower floor element according to the invention. In addition to its permanently elastic properties, the adhesive itself has waterproof properties, so that when applied over the entire surface, it provides a supplementary sealing layer.

[0031] The high material compatibility also allows the sealing element to be arranged on the surface of the rigid foam board, for example, glued, or applied to one side of the rigid foam board instead of a protective layer. Optionally, the sealing elements can also function as a protective layer on both sides of the rigid foam board.

[0032] The professional installation of sealing elements usually requires a watertight connection to the adjacent components. According to a further design of the building board, the sealing element can extend laterally beyond the composite board, at least in sections, i.e., in extension of the composite board plane. d. h. The building board can have a sealing element that protrudes beyond the edge of the composite panel. Such a building board is suitable for connecting to the adjacent components in such a way that the watertight connection can be created easily, reproducibly, and reliably, without the need for additional sealing tapes. The protruding edge and the sealing element can be integral or multi-part. In a multi-part design, the connection between the sealing element on the composite panel and the protruding edge is visibly watertight.

[0033] The rigid foam core made of polyethylene terephthalate is a thermoformable, flexible sheet, allowing the sheet to be shaped before the stiffening protective layers are formed. This shaping allows the rigid foam core to be adapted to structural conditions, for example. Deformations within a surface are also possible. For example, the rigid foam sheet can be uneven at least in sections and / or at least on one side. d. h. The points on a surface of the rigid foam board are not in a single plane. Optionally, the board may have recesses, projections, or beveled areas.

[0034] Structural and insulating foams made of polyethylene terephthalate have low densities in the range of 30 to approximately 300 kg / m³, preferably from 60 to approximately 300 kg / m³, which allows for a variety of uses and designs that also achieve the desired stability and insulation. The high stability is achieved, among other things, by the compressive strength of the polyethylene terephthalate, which can be in the range of 100 to 2,000 kPa, for example, in the range of 200 to 2,000 kPa. The low density and high stability, combined with the versatility of the surface, also allows the prefabrication of finished room components, such as shower cubicles or entire bathroom cubicles, using the described rigid foam board.

[0035] The supporting element is installed on a suitable subfloor or substructure. It is strong enough, in conjunction with the subfloor or substructure, to support the standard weight of the shower user, ensuring that the sealing element's watertight connections to adjacent components and drains do not crack.

[0036] Often, such shower floor elements require a low height so that they can be fully integrated into the floor structure, possibly including drainage pipes and / or a step or threshold. To reduce the installation height, shower floor elements can be covered with a tile covering produced on site or with a surface-finished, slab-like covering element. The latter can be thinner than tile and can also be designed very flexibly and individually according to customer requirements, both in terms of geometry and surface design.

[0037] The cover element can be a separate element or, according to a further embodiment, can be formed integrally with the building board. Such a one-piece construction with the building board can be achieved, for example, by a coating that creates a surface ready for use as the shower floor element. Such a surface-finished layer of the shower floor element can, for example, be a coating made of a mineral material or a surface-finished concrete filler.

[0038] If the shower floor element is made up of several parts, other panel coverings can be used for the cover element as an alternative to tiling or a single or multi-part mineral panel, such as compact laminate panels, also known as HPL panels (High Pressure Laminate), or similar.

[0039] Both the integral and two-part design of the supporting element and cover element of the shower floor element can be single-sided, in this case, apparently on the top, or double-sided. A double-sided design gives the shower floor element greater stability, for example, during handling during production, storage, transport, and installation, as well as greater dimensional stability. Both are essential quality features, especially for the increasingly thinner shower floor elements for flush-to-floor installation.

[0040] Due to the high material compatibility of the rigid foam core made of polyethylene terephthalate, such a surface-finished coating can also be used on one or both sides, which simultaneously functions as a protective layer(s) of the building board.

[0041] The shower water drain is incorporated into the supporting element. This includes a drain opening and a drainage area incorporated into the top of the supporting element. The latter has a gradient running towards the drain opening, whereby the layout and degree of the gradient can be varied according to planning specifications and regulations. The top of the supporting element can also have a flat, d. h. have a level edge area. Such an edge area, which extends above the drain opening by the amount of the gradient, is apparently intended to prevent standing water in the shower floor element from flowing over the edge at lower points or from accumulating on upstanding walls. The width of the edge area can be very variable, even very narrow.

[0042] Due to the horizontal installation of the shower floor element, the top and bottom surfaces of the element in question, following the direction of gravity, are usually referred to as the top and bottom, or front and back, of these elements. The surfaces connecting the two surfaces are, also in accordance with the commonly used term, the side surfaces.

[0043] The generic shower floor element further comprises a cover element, which can be designed, for example, as a cover plate or cover layer. The cover element also has a drain opening, which visibly corresponds in position and size to the drain opening of the support element. The cover element is firmly connected to the top of the support element in a suitable manner. It can be designed as a single- or multi-part plate, as a floor covering applied to the support element on site, for example, tile flooring, or as a coating of the support element. A mineral material, for example, is suitable as a surface-finished cover element or coating of the support element.

[0044] The generic shower floor element further comprises a sealing element, which serves to create and maintain a waterproof layer between the support element and the cover element, as well as to ensure a waterproof connection of the shower floor element to the drain and the adjacent structural elements. For this purpose, the sealing element is arranged between the cover element and the support element. Depending on the design of the shower floor element, the sealing element can, as already mentioned, be that of the above-described support element with a rigid foam core made of polyethylene terephthalate.

[0045] The sealing element can extend laterally beyond the cover element and the supporting element, at least in sections, and optionally completely, to create seamless connections to adjacent structural elements. Apparently, during the completion of the drain, a drainage opening will also be created in the sealing element, corresponding to the previously mentioned ones. Regarding the sealing element, please refer to the above explanations.

[0046] Such a shower floor element can be constructed in layers on site. Alternatively, the shower floor element can also be prefabricated with the layered structure described.

[0047] Such shower floor elements are particularly used in floor-level showers, where the shower floor is at the same or only slightly higher level as the surrounding floor. A key advantage of these floor-level showers is improved accessibility due to the absence of steps.

[0048] However, in order to ensure that the draining shower water is safely directed into the overflow even in the event of a high water flow and that the transitions to the surrounding walls and floors are reliably and permanently protected against standing water, the drain openings and the gradient of the shower floor leading to the latter must be designed accordingly and, if necessary, combined with suitable floor thresholds or low-height steps from the shower floor element to the adjacent floor.

[0049] It is advantageous that the rigid foam core is deformable as described above, so that the slope and other uneven areas of the rigid foam board can be formed by deep drawing the supporting element, as described in more detail below. This enables efficient production of the supporting element and a wide range of design options with regard to its geometry.

[0050] Another aspect relates to a method for producing a shower floor element. The method comprises: providing a support element, arranging a sealing element on the support element, and arranging a cover element on the sealing element.

[0051] According to the invention, a rigid foam board is arranged as the supporting element, wherein the rigid foam board is made of polyethylene terephthalate, and a sealing element is arranged on and / or in the rigid foam board (3) using a silane-based polymer adhesive. To produce a waterproof layer, the sealing element is bonded to the rigid foam board using the polymer adhesive.

[0052] Using the proposed method, one of the shower floor elements described above can be manufactured. The explanations for these shower floor elements are applicable to their manufacturing process. The advantages of the shower floor elements are correspondingly linked to the manufacturing process.

[0053] According to various embodiments, the provision of the support element can comprise the following steps: providing a rigid foam board made of polyethylene terephthalate, optionally arranging a protective layer with a thickness of less than or equal to 0.3 mm, preferably less than or equal to 0.2 mm, on a first surface of the rigid foam board, and producing a waterproof layer by arranging a sealing element on the other surface of the rigid foam board and / or as a layer within the rigid foam board. In other words, the building board can be formed by means of the aforementioned steps. Optionally, a further protective layer can be formed on the second surface of the rigid foam board. The surface here refers to the surfaces of the top and bottom of the plate-shaped element.

[0054] According to further design variants, the sealing element and the rigid foam board can be glued together, optionally glued over the entire surface.

[0055] To bond the sealing element to the composite panel or the rigid foam panel, an adhesive can be sprayed onto a surface of the sealing element and / or a surface of the composite panel or the rigid foam panel.

[0056] Spraying the adhesive is a simple application method that allows for a very even application. This creates a bond with homogeneous properties, which has a positive effect on the mechanical properties of the bond and the long-term stability of the building board. Furthermore, as shown above, it can create an additional surface seal.

[0057] Optionally, the adhesive can be heated before spraying, z. B. to a temperature in the range between 20 °C and 40 °C, for example 30 °C. The spraying can be carried out, for example, at a temperature in the range between 15 °C and 35 °C, for example at 20 °C. For this purpose, components of the spray device, such as . B. hoses, nozzles, etc., are heated to a temperature in the specified range.

[0058] Heating the adhesive can reduce its viscosity, allowing the use of adhesives that would be too solid at ambient temperature for use in a spray process. Furthermore, the adhesive can be applied more evenly, further improving the mechanical properties of the bond.

[0059] Preferably, the sealing element and the rigid foam plate can be bonded together using a silane-based polymer adhesive.

[0060] The sealing element can be bonded to the rigid foam board using a stamp or a membrane. The surfaces of the rigid foam board and the sealing element to be bonded are positioned opposite each other or on top of each other at a certain distance. The sealing element is then pressed onto the composite board or rigid foam board using the stamp or membrane until an adhesive bond is established. Optionally, the membrane can be pressed onto the composite board or rigid foam board using a gas- or liquid-filled stamp pad. The membrane can also optionally be part of the stamp pad.

[0061] The use of a stamp, a stamp pad, or a membrane to create the adhesive bond allows for uniform and full-surface contact between the two surfaces to be bonded, thus ensuring reliable bonding and the formation of a homogeneous sealing surface. Furthermore, the adhesive bond can be formed particularly quickly using the described bonding process.

[0062] Optionally, uneven sections and / or a gradient can be created in the support element by deep drawing during the production of the support element. Maintaining the thickness of the rigid foam board in the deep-drawn area, as is common with deep-drawing processes for metal plates, is not required. Depending on the desired profile of the rigid foam board, the recesses can be formed on one or both sides. Deep drawing can be performed in various ways, for example, with a deep-drawing tool, such as a die and punch, or with a deep-drawing medium, such as a liquid- or gas-filled stamp pad.

[0063] According to one embodiment of the method, the gradient is introduced into the upper side of the support element by placing its rigid foam plate on an optionally flat base and deforming it on the upper side using a stamp or stamp pad, optionally also with a membrane in between. The stamp pad is a pad, preferably filled with a liquid, optionally with a gas, whose underside surface shape corresponds to that of the gradient to be created.

[0064] According to a further embodiment, the deep drawing for producing the gradient can be combined with the bonding of the sealing element to the rigid foam board and alternatively carried out in one or two successive process steps.

[0065] Deep drawing can optionally be carried out under the influence of heat, whereby the temperature is obviously selected in such a range that avoids a weakening of the load-bearing properties or structural damage to the rigid foam that could impair the usability of the rigid foam board and / or the sealing element.

[0066] The invention will be explained in more detail below using exemplary embodiments. Those skilled in the art would combine the features described above and below in further exemplary embodiments as far as they deem appropriate. The accompanying drawings show in Fig. 1A a supporting element of a shower floor element in exploded view, Fig. 1B a shower floor element according to the invention using a supporting element according to Fig. 1A , also in exploded view, and Fig. 2 a shower floor element in plan view.

[0067] The figures serve only to illustrate the invention. They show only the necessary details. They make no claim to completeness or scale.

[0068] Fig. 1 shows a supporting element 1, which is used for a shower floor element 7 ( Fig. 2 ) can be used, in a schematic representation. The support element 1 comprises a rigid foam plate 3 with the sealing element 5 arranged on top. The rigid foam plate 3 is made of polyethylene terephthalate.

[0069] The sealing element 5 is bonded to the rigid foam board 3 over its entire surface using an adhesive layer 4 of a one-component, air- and moisture-curing MS polymer-based construction adhesive. The sealing element 5 has, by way of example but not by way of limitation, the size of the rigid foam board 3.

[0070] Fig. 1B shows the supporting element 1 with rigid foam plate 3 and sealing element 5 according to Fig. 1A In this respect, reference is made to the previous explanations.

[0071] A further plate-like element is applied to the top of the sealing element 5 using a suitable adhesive material (not shown). The further plate-like element serves as a cover element 6 and forms the finished surface of a shower floor element 7. The cover element 6 is designed, by way of example but not by way of limitation, as a multi-part plate, for example, a tile covering.

[0072] Fig. 2 shows a shower floor element 7 in plan view. The upper, in Fig. 2 The visible end of the shower floor element 7 is formed by a one-piece, surface-finished cover element 6 made of, for example, but not limited to, a mineral material or plastic. The cover element 6 is as shown in Fig. 1B described on the supporting element (in Fig. 2 not shown) arranged and fixed.

[0073] The cover element 6 has a drainage channel 8, in which a circular drainage opening 9 is formed in the center. The cover element 6 also has expertly formed slopes 10, which extend from each side edge of the cover element 6 to the corresponding side edge of the drainage channel 8.

[0074] The sealing element 5 arranged under the cover element 6 has a circumferential projection 11, which extends laterally over the building board (in Fig. 2 not shown). The corner areas of the projection 11 are designed such that the projection 11 can be applied to adjacent vertical components (not shown) if necessary and the corner areas can be overlapped. Bezugszeichenliste

[0075] 1Building board 3Rigid foam board 4Adhesive layer 5Sealing element 6Cover element 7Shower floor element 8Drain channel 9Drain opening 10Gradient 11Overhang

Claims

1. Shower floor element (7) for producing the standing surface of a shower area, with a rigid foam plate (3) as a supporting element and a cover element (6) arranged on the top and with a sealing element (5) located under the cover element (6) for producing a waterproof layer, characterized in that the rigid foam plate (3) is made of polyethylene terephthalate and the sealing element (5) and the rigid foam plate (3) are glued together with a silane-based polymer adhesive.

2. Shower floor element (7) according to claim 1, characterized in that the rigid foam plate (3) consists of a recycled polyethylene terephthalate.

3. Shower floor element (7) according to one of the preceding claims, characterized in that the rigid foam plate (3) has a protective layer with a layer thickness of less than or equal to 0.3 mm on the underside or no such protective layer.

4. Shower floor element (7) according to one of the preceding claims, characterized in that the sealing element (5) is designed as a film or fleece and / or as a sealing sheet or as a coating.

5. Shower floor element (7) according to one of the preceding claims, characterized in that the sealing element (5) is formed on a surface of the rigid foam plate (3) and / or as a layer within the rigid foam plate (3).

6. Shower floor element (7) according to one of the preceding claims, characterized in that the sealing element (5) projects laterally beyond the composite panel (2) at least in sections.

7. Shower floor element (7) according to one of the preceding claims, characterized in that the rigid foam plate (3) is formed in multiple layers and / or is uneven at least in sections and / or uneven at least on one side.

8. Shower floor element (7) according to one of the preceding claims, characterized in that the rigid foam plate (3) has a density in the range between 30 and 300 kg / m3 and / or a compressive strength in the range of 0.2 to 2.0 MPa.

9. Shower floor element (7) according to one of the preceding claims, characterized in that the sealing element (5) and the rigid foam plate (3) are glued together over their entire surface.

10. Shower floor element (7) according to one of the preceding claims, characterized in that the cover element (6) is formed integrally with the rigid foam plate (3) and the sealing element (5).

11. Shower floor element (7) according to one of the preceding claims, characterized in that the shower floor element (7) has a drain opening (9) and in its upper side a slope (10) running towards the drain opening (9), which is formed by deep drawing in the rigid foam plate (3).

12. Method for producing a shower floor element (7), the method comprising: - Providing a rigid foam plate (3) as a supporting element, - arranging a sealing element (5) to produce a waterproof layer and - Arranging a cover element (6) on the support element, characterized in that the rigid foam plate (3) is made of polyethylene terephthalate and the sealing element (5) is arranged on and / or in the rigid foam plate (3), wherein the sealing element (5) is glued to the rigid foam plate (3) by means of a silane-based polymer adhesive to produce a waterproof layer.

13. Method according to claim 12, characterized in that the polymer adhesive is applied and / or sprayed onto at least one of the surfaces to be bonded together over the entire surface.

14. Method according to claim 12 or 13, characterized in that the polymer adhesive is heated to a temperature in the range between 20 °C and 40 °C before it is applied to a surface.

15. Method according to one of claims 12 to 14, characterized in that the bonding of the surfaces of the rigid foam plate and the sealing element and / or the imprinting of a slope into the upper side of the rigid foam plate is carried out by means of a stamp or a gas- or liquid-filled stamp pad.