Floor heating panel

Abstract

Underfloor heating panel consisting of a foam panel (2) with expanded polyalkylene terephthalate beads.

Description

[0001] The present invention relates to an underfloor heating panel comprising a foam panel with expanded beads made of polyalkylene terephthalate, preferably polyethylene terephthalate.

[0002] Underfloor heating panels are typically made of EPS or XPS materials, whose CS 10 compressive strength is generally 150-400 kPa (according to EN 681-1). These panels are too soft for direct installation of floor coverings, and the installation must be reinforced with a load-bearing layer applied to the panel (usually plasterboard or rubber-plastic reinforcement panels). This increases the installation height and requires additional work phases during installation.

[0003] The aim of the present invention is to provide an improved underfloor heating panel.

[0004] The present invention provides an underfloor heating panel according to claim 1. Preferred embodiments are set out in the subclaims.

[0005] According to the present invention, the underfloor heating panel consists of a foam panel with expanded beads made of polyalkylene terephthalate, preferably polyethylene terephthalate. The expanded beads can be produced as described, for example, in EP 2567799 B9.

[0006] Preferably, the expanded beads comprise a cellular core encapsulated by a compact skin and have a density of less than 400 kg / m 3 according to DIN ISO 1183, and wherein the expanded beads have an intrinsic viscosity of at least 0.69 dl / g according to ASTM D4603-03 and a melt viscosity η 0 of more than 300 Pa.s according to ASTM D4440 at 280°C. Preferably, the compact skin has a thickness of less than 120 µm. Preferably, the cellular core comprises a microcellular layer and a fine-cell center and has a cell size of less than 400 µm. Preferably, the particle size is between 1 and 20 mm. Preferably, the degree of crystallinity of the beads is less than 10%. Preferably, the polyalkylene terephthalate resin has an intrinsic viscosity of less than 1.0 dl / g according to ASTM D4603-03 before the expansion process.Preferably, the polyalkylene terephthalate is a polyethylene terephthalate, more preferably a polyethylene terephthalate selected from a bottle-grade PET resin with an inherent viscosity (IV) between 0.75 and 1.00 dl / g according to ASTM D4603-03, a fiber-grade PET resin with an IV between 0.55 and 0.67 dl / g according to ASTM D4603-03, or a recycled (post-consumer) PET resin with an inherent viscosity (IV) below 1.0 dl / g according to ASTM D4603-03, or a mixture thereof. Preferably, the beads are prepared using a multifunctional chain-extending compound, preferably selected from tetracarboxylic dianhydride, polyepoxides, oxazolines, oxazines, acyllactams, or sterically hindered phenolic antioxidants, or a mixture thereof.

[0007] Preferably, the expanded beads within the foam board are vertically aligned. Vertically aligned PET foam boards have a compressive strength (CS 10) of 1600-4600 kPa, depending on the material density. This high compressive strength allows for the direct installation of tiles on top of the installed underfloor heating board. This allows for a lower installation height and thus makes it more suitable for renovation projects. Regarding the system's installation, the absence of reinforcement reduces the number of work phases, shortens installation time, and lowers overall costs.

[0008] Preferably, the expanded polyalkylene terephthalate beads are made from recycled polyalkylene terephthalate, more preferably recycled polyethylene terephthalate. Recycled polyethylene terephthalate is also referred to as "post-consumer PET." The beads can be manufactured from a resin in the form of flakes, powder, agglomerates, or granules obtained from the recycling of any PET-containing waste stream and having an inherent viscosity (IV) of usually, but not exclusively, less than 1.0 dl / g.

[0009] The term "post-consumer" is defined as material that is reintroduced into the process—i.e., recycled—after prior processing and / or use, e.g., as PET bottles, PET articles, polyester waste, or recycled polyester. The waste stream is collected from household waste, industrial waste, or used bottles. After shredding, the waste is processed into PET flakes through pre-separation, washing, separation, and drying.

[0010] The recycled PET flakes can be foamed directly or after a granulation process. In the latter case, the recycled PET is provided in the form of granules / chips. The used PET resin may contain polyolefin, polyamide, PVC, or other impurities in a total amount generally less than 5.0% by weight.

[0011] All of the above-mentioned alkylene terephthalate polymers can be used either as a single polymer or as a mixture thereof in the form of granules, agglomerates, powders or flakes.

[0012] It is also possible to process a polymer blend containing polyalkylene terephthalate to produce such expanded beads. Possible blend partners can be selected from, but are not limited to, PEN, PC, LLDPE, LDPE, PP, SAN, SEBS, PSU, PES, PA, PPE, LCP, PMMA, or a mixture thereof.

[0013] The foam board preferably has a rectangular shape.

[0014] Preferably, the foam plate has grooves for a piping system, which are preferably laminated with, preferably separate, strips of aluminum foil or aluminum plates.

[0015] Preferably, the foam plate has longitudinal grooves or longitudinal grooves and short-side grooves or transverse grooves connecting the longitudinal grooves.

[0016] Preferably, the grooves have an omega shape so that the conduit system can be pressed into the grooves and then held in place.

[0017] Preferably, the foam plate consists of plastic tubes, preferably of a polyolefin, more preferably of a cross-linked polyolefin, in particular of cross-linked polyethylene (PEX).

[0018] The polyolefin used for the pipe is not limited. It is possible to use non-crosslinked polyolefins. Preferably, the non-crosslinked polyolefins are selected from the group consisting of polyethylene, preferably PE-RT (polyethylene with increased temperature resistance), polypropylene, preferably PPR (approximately 5% PE in the molecular chain of PP random uniform polymer (random copolymer), polybutylene terephthalate (PBT), and mixtures thereof. Alternatively, a crosslinked polyolefin can also be used. An example of a crosslinked polyolefin is crosslinked polyethylene (PEX), which is preferably made from high-density polyethylene (HDPE). PEX contains crosslinked bonds in the polymer structure, transforming the thermoplastic into a thermoset. Crosslinking is achieved during or after the extrusion of the pipes. The degree of crosslinking is preferably between 60 and 90%.A higher degree of cross-linking could lead to brittleness and stress cracking in the material, while a lower degree of cross-linking could result in an inner pipe with poorer physical properties. The degree of cross-linking is preferably specified in accordance with ASTM F876 or ISO 15875. Cross-linked polyethylene (PEX) is the preferred material for the one or more inner pipes due to its material properties, particularly its flexibility and high-temperature resistance.

[0019] As a reference example, a method for installing floor coverings using the underfloor heating panel according to the invention is provided. The method comprises the following steps: bonding the floor to the UFH panel; laying the panel and the pipes; applying the tile adhesive; and laying the tiles.

[0020] Compared to a prior art flooring installation method using a conventional underfloor heating panel, fewer components and fewer installation phases are required. This means that when using the underfloor heating panel according to the invention, only the tiles, underfloor heating panel with pipe system, and edge strip are required. In contrast, the prior art also requires a reinforcement layer (e.g., made of plaster) with joint tape and an edge strip. Furthermore, the prior art requires the following additional installation phases: installation of the edge support; adhesive on top of the underfloor heating panel; installation of the reinforcement layer; bonding all seams of the reinforcement layer panels; and application of an optional primer on top of the reinforcement layer.

[0021] The underfloor heating panel according to the invention thus enables a lower installation height for the underfloor heating panel – floor construction for tiles – and leads to easier installation. This reduces overall installation costs. Furthermore, it is also possible to reduce the environmental impact by using recycled PET waste for the production of the underfloor heating panels. Finally, it should be noted that the underfloor heating panels according to the invention are themselves recyclable.

[0022] In the figures: Fig. 1 shows a floor heating panel comprising a foam board with expanded beads of polyalkylene terephthalate according to the present invention. Fig. 2 shows an expanded view of a groove in the foam board, wherein the groove encloses a tube. Fig. 3shows a graph showing the compression test results for different materials for the foam board beads. Fig. 4 shows how underfloor heating panels are installed according to the state of the art Fig. 5 shows how the underfloor heating panels according to the invention are laid

[0023] Fig. 1 shows an underfloor heating panel (1) comprising a foam panel (2) with expanded polyalkylene terephthalate beads according to the present invention. The foam panel has longitudinal grooves (3) and short-side grooves (4). An aluminum foil (5), preferably with a thickness of 0.05 to 0.2 mm, in particular 0.1 mm, is laminated to the upper side of the underfloor heating panel, corresponding to the longitudinal grooves.

[0024] Fig. 2is an expanded view of a longitudinal groove (6), wherein aluminum foil strips (7) are laminated on the inside, in particular on the bottom, of the longitudinal groove (6).

[0025] Fig. 3 shows a graph showing the compression test results for various foam board bead materials. Specifically, the compression test results at 10% elongation are shown for XPS, horizontally oriented PET, and vertically oriented PET samples with densities of 100, 150, and 250 kg / m³, respectively.

[0026] Fig. 4shows how underfloor heating panels are installed according to the state of the art. The following components are used: tile covering (9); reinforcement layer with seam tape (10); underfloor heating panel with pipe system (11); edge support (12); and edge strip (13). The state-of-the-art method for installing tiles using the state-of-the-art underfloor heating panels typically includes the following steps: 1. Bonding the floor base and UFH board 2. Laying the edge support 3. Laying boards and pipes 4. Applying adhesive on top of the UFH board 5. Installing the reinforcement layer 6. Masking all seams of the reinforcement layer boards 7. Optional primer on the reinforcement layer 8. Tile adhesive + tiling

[0027] Fig. 5. shows how to install floor heating panels according to the present invention. The following components are required: floor heating panels according to the present invention with pipe system (14); tiles (15); and edge strips (in Fig. 5 not shown). Reference symbol

[0028] 1Underfloor heating panel 2Foam panel 3Longitudinal grooves 4Short-side grooves 5Aluminium foil laminated to the top of the underfloor heating panel according to the longitudinal grooves 6Groove 7Aluminium foil strip 8Pipe 9Tiles 10Reinforcing layer with taped seams 11Underfloor heating panel with piping system according to the prior art 12Edge support 13Edge strip 14Underfloor heating panel with piping according to the present invention 15Tiles

Claims

1. Underfloor heating panel (1), consisting of a foam panel (2) with expanded polyalkylene terephthalate beads.

2. Underfloor heating panel according to claim 1, wherein the polyalkylene terephthalate is a polyethylene terephthalate.

3. Underfloor heating panel (1) according to claim 1 or 2, wherein the expanded beads comprise a cellular core encapsulated by a compact skin and have a density below 400 kg / m 3 according to DIN ISO 1183, and wherein the expanded beads have an intrinsic viscosity of at least 0.69 dl / g according to ASTM D4603-03 and a melt viscosity η0 of more than 300 Pa.s according to ASTM D4440 at 280°C.

4. Underfloor heating panel (1) according to one of the preceding claims, wherein the expanded beads are aligned vertically in the foam panel (2).

5. Underfloor heating panel (1) according to one of the preceding claims, wherein the expanded beads of polyalkylene terephthalate comprise or preferably consist of recycled polyalkylene terephthalate.

6. Underfloor heating panel (1) according to one of the preceding claims, wherein the foam panel (2) has a rectangular shape.

7. Underfloor heating panel (1) according to one of the preceding claims, wherein the foam panel (2) has grooves (6) for pipe systems, which are preferably laminated with, preferably separate, strips of aluminum foil or aluminum panels.

8. Underfloor heating panel (1) according to one of the preceding claims, wherein the foam panel (2) has longitudinal grooves (6) and short-side grooves connecting the longitudinal grooves (6).

9. Underfloor heating plate (1) according to claim 8, wherein the aluminum foil is laminated on the upper side of the plate (2) corresponding to the longitudinal grooves (6).

10. Underfloor heating panel (1) according to claim 8 or 9, wherein the grooves (6) have an omega-shaped form so that the pipe system can be pressed into the grooves (6) and then held in place.

11. Underfloor heating panel (1) according to one of the preceding claims, wherein the foam panel (2) comprises plastic pipes, which preferably consist of a polyolefin, more preferably of a cross-linked polyolefin, in particular of cross-linked polyethylene (PEX).

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