Method for installing a polymer panel on a wall, for the purpose of creating a wall covering

Abstract

The invention relates to a method of installing a polymer panel on a vertical wall for the purpose of creating a wall covering, remarkable in that it consists of gluing an entire surface of the panel to the vertical wall with a layer of glue based on silane-modified polymers.

Description

Title of the invention: Method for installing a polymer panel on a wall, for the creation of a wall covering. Technical field

[0001] The present invention relates to the field of wall cladding panels and their installation method. Previous art

[0002] It is known from the prior art to glue polymeric panels, such as panels made from PVC, PET or PETg, onto a wall of any type, for example plasterboard or fiber cement, bricks, cement, tiles, wood, etc. for the purpose of creating a wall covering.

[0003] These panels are generally installed side by side, and one of the main techniques used involves applying an acrylic adhesive to the entire surface of the panel against the wall. Other types of adhesive, such as polyurethane or neoprene-based adhesives, are not recommended because of the VOCs they can generate or because they may require gluing both the panel and the wall, which increases installation time.

[0004] In practice, the acrylic glue is applied using a notched spatula and then, after waiting for a recommended setting time, i.e. a drying time for the glue, the panel is positioned on the glue, and pressed against the wall to be covered.

[0005] The disadvantage of this solution, besides the necessary gumming time, lies in the fact that, depending on the installation temperature, the operating temperature, and the temperature variations to which the panel is exposed, there are problems of dimensional stability and thermal expansion of the panel, which can harm the general aesthetics of the coating or even lead to partial detachment of the panel.

[0006] To remedy this problem, it is known to install the panels in a room with an ambient temperature of approximately 20°C and to leave a gap between two adjacent panels, typically around 2 mm, which detracts from the overall aesthetics. This gap may be increased by one millimeter per linear meter of panel installed for every 5°C of anticipated room temperature variation.

[0007] Furthermore, to improve the overall aesthetics and / or ensure a seal, it is also known to create, in addition to the gap, a joint between two adjacent panels, for example by a silicone bead, or a hot-welded PVC bead or to install a finishing profile to conceal the gap.

[0008] This expansion phenomenon is exacerbated when the panel to be installed has a large dimensions, for example, greater than 2 meters or even greater than 3 meters.

[0009] In such a situation, it is recommended to cut the panel into several smaller panels to maximize the number of joints and / or the number of gaps between the panels to absorb thermal expansion. Description of the invention

[0010] One of the aims of the invention is to overcome the disadvantages of the prior art, by proposing a method of installing a polymer panel on a wall for the purpose of creating a wall covering, which makes it possible to reduce, or even avoid, the problems related to thermal expansion.

[0011] Another objective is to provide such a process which is simple with a short exposure time.

[0012] Another objective is to provide such a process whose implementation generates little or no VOCs.

[0013] For this purpose, a method of installing a polymer panel on a wall has been developed, remarkable in that it consists of gluing an entire surface of the panel to the wall with a layer of glue based on silane-modified polymers.

[0014] The nature of the vertical wall is of little importance, but according to the Applicant it is rather the relationship between the glue and the panel which makes it possible to solve the problem posed.

[0015] Indeed, the Applicant has observed that, although not exhibiting superior adhesion compared to acrylic adhesives, silane-modified polymer adhesives reduce or even eliminate thermal expansion problems. In practice, silane-modified polymer adhesives are not used for full-surface bonding, and even less so for bonding large surface areas exceeding 2.5 m², nor for wall covering applications. They are more commonly used for bonding two dissimilar materials together.

[0016] The invention makes it possible to place panels side by side, with a reduced or even zero gap between them, and without the need to make joints, or to cut the panel into small dimensions.

[0017] Moreover, this type of glue does not require any tack time so the application process is quick.

[0018] Installation is therefore facilitated, and the inherent costs are reduced.

[0019] Another advantage is that this type of glue does not contain isocyanate.

[0020] Bonding the entire surface of the panel also allows, in addition to the fact of to retain the thermal expansion of the panel, to reduce the spread of fire by avoiding air currents and chimney effects between the panel and the wall during a fire.

[0021] To facilitate the application of the silane-modified polymer adhesive, the Applicant uses a silane-modified polymer adhesive whose viscosity has been modified compared to commonly available adhesives of this type, and which is in the range of 50 to 500 Pa·s at 20 rpm, preferably 75 to 200 Pa·s at 20 rpm, measured at 20°C using a Brookfield-type rotary viscometer with spindle No. 7, which measures viscosity by analyzing the torque required to rotate the spindle at a constant speed in an immersed liquid. The torque is proportional to the viscous drag on the spindle and therefore to the viscosity of the sample.

[0022] This viscosity facilitates the application of the adhesive, particularly with a spatula, preferably a notched one. The adhesive can be applied to vertical surfaces without smoothing.

[0023] Preferably, and in order to facilitate implementation, the layer of glue is applied to the wall against which the panel is intended to be placed, and on a surface corresponding at least to that of the panel, the process then consisting of placing the panel on the layer of glue.

[0024] In practice, the glue is applied in an amount between 100 and 500 g / m2, preferably between 250 and 320 g / m2, which is sufficient to retain the thermal expansion of the panel.

[0025] The invention makes it possible to glue polymer panels having a thickness of between 1 and 6 mm, preferably between 1 and 3 mm, for example 2 mm, and a dimension greater than 2.5m, or even 3m.

[0026] The invention also relates to wall covering in the form of at least one panel glued on the full surface against a wall, with a glue based on silane-modified polymers. Detailed description of the invention

[0027] The invention relates to a particular method of installing one or more panels made from polymer, such as PVC, PET, or PETg, on a vertical wall for the purpose of creating a wall covering.

[0028] In practice, the vertical wall consists of a wall made of plasterboard or fiber cement, bricks, cement, tiles, wood, concrete or any other material.

[0029] The invention consists of gluing the panel with a silane-modified polymer-based adhesive in order to limit, or even eliminate, the thermal expansion phenomena that the installed panels may undergo, including panels with a thickness between 1 and 6 mm, preferably between 1 and 3 mm, for example 2 mm, of large dimensions, such as a width or length greater than 2.5m, or even 3m.

[0030] The adhesive used is, for example, a solvent-free polymer adhesive with a siloxane or silicone as the main chain (Si-O-Si), in which the silicon may be substituted with a hydrogen atom and / or a carbon group, and with ends terminated by a silane or a siloxane, such as methoxysilane, trimethoxyphenylsilane, or trimethoxyvinylsilane. The adhesive is a thixotropic, single-component adhesive and also includes mineral fillers and additives.

[0031] Silane-modified polymer-based adhesive has a lower peel strength than acrylic adhesive due to the molecular structure of the silane-modified polymer, so the use of this type of adhesive to limit the thermal expansion phenomena of the panel is not obvious.

[0032] In practice, the glue used has a viscosity of the order of 50 to 500 Pa.s at 20 rpm, preferably of 75 to 200 Pa.s at 20 rpm measured at 20°C according to a measurement with a rotary viscometer of the "Brookfield" type with the movable part no. 7 and is preferably applied with a glue spatula, preferably notched of type A2, according to the TKB A2 standard.

[0033] The invention consists of uniformly applying a layer of adhesive to the vertical surface using a notched trowel of type A2. The adhesive should preferably be acclimatized to room temperature. The vertical surface must be dry, clean, and free of grease. Application in a humid environment is also possible because water allows for a faster setting of the silane-modified polymer-based adhesive.

[0034] The layer of glue must cover a surface corresponding at least to that of the panel to be glued, and must be applied with an amount of the order of 100 to 500 g / m2, preferably 250 to 320 g / m2.

[0035] Under ideal installation conditions, the room temperature in which the panel is to be installed is between 18 and 25 °C, the temperature of the vertical wall is above 15 °C, and the relative humidity is below 65%. Low temperature and low humidity prolong working, setting, and drying times, while high temperature and high humidity reduce them.

[0036] The invention thus makes it possible to limit, or even eliminate, the thermal expansion of the panels, and therefore the need to cut the panels into small dimensions, leave gaps between the panels, or create joints. Of course, if installation takes place in a humid environment, it will still be possible to create a joint to ensure watertightness. Installation time and associated costs are reduced, without affecting the overall aesthetics of the installed covering.

[0037] Tests were carried out on PVC and PETg panels of 800 mm to 900 mm in length and 300 mm in width placed on plasterboard and fiber cement boards, at 23 °C ambient temperature, and then carrying out temperature variations (delta up to 32°C, from 23 to 55°C or delta of 27°C between 11°C and 38°C) in cycling.

[0038] Expansion is measured in the width direction of the panels. These tests have shown that on the different substrates tested, the expansion of PVC or PETg panels bonded with silane-modified polymer adhesive is less than 0.02 mm per linear meter of panel per 5°C of temperature variation, i.e., a coefficient of expansion less than 0.4 x 10⁵ OC*.

[0039] In comparison, when the panels are glued with a conventional acrylic-type glue, the expansion is greater than 0.15 mm / ml / 5°C, i.e., a coefficient of expansion greater than 3.105 T1, and greater than 0.2 mm / ml / 5°C, i.e., a coefficient of expansion greater than 4.2.105 °C 1, when the panels are free (not glued).

[0040] Other tests have been carried out and demonstrate that the process according to the invention makes it possible to block the phenomena of thermal expansion of the 2.30 m wide panels placed on plasterboard at 23°C (delta of 13°C) and mounted at 36°C in cycling.

[0041] Shear strength tests were also carried out by the Applicant to determine the average strength of the material when subjected to displacement parallel to its support. The shear measurements were performed in accordance with standard NF EN 1373.

[0042] The results are compiled in the table below for a panel glued with acrylic glue.

[0043] [Tables 1] Test Method Technical Characteristics Units Number of Measurements Average Value NF EN ISO 24346 Total Panel Thickness mm 18 1.84 NF EN ISO 23997 Total Panel Mass per Unit g / m² 5 2440 EN 1373- May 2015 Bonding to fiber cement with acrylic adhesive followed by shear test 27 days at 23°C MPa 5 0.35 7 days at 23°C + 20 days at 50°C 0.97 Bonding with silane-modified polymer-based adhesive to fiber cement followed by shear test 27 days at 23°C MPa 5 >0.95 7 days at 23°C + 20 days at 50°C >1.23

[0044] As shown in the table above, the shear strength of the silane-modified polymer adhesive is greater than that of the acrylic adhesive. The test could not provide a precise value because the measurement limits were reached. However, the strength measured before the limit was significantly greater than that of the acrylic adhesive.

[0045] The invention therefore makes it possible to provide a method for installing panels, and the resulting wall covering, which reduces or even avoids problems related to thermal expansion, while offering satisfactory shear resistance.

Claims

Demands

1. A method for installing a polymer panel on a vertical wall for the purpose of creating a wall covering characterized in that it consists of gluing an entire surface of the panel to the vertical wall with a layer of thixotropic single-component adhesive based on silane-modified polymers also comprising mineral fillers and additives, and in that the adhesive is applied in an amount between 100 and 500 g / m2, preferably between 250 and 320 g / m2.

2. A method according to claim 1, characterized in that the applied glue has a viscosity of the order of 50 to 500 Pa.s at 20 rpm, preferably of 75 to 200 Pa.s at 20 rpm measured at 20°C with a rotating viscometer of the "Brookfield" type with spindle no.

7.

3. Method according to claim 1, characterized in that it consists of applying the layer of glue to the wall over a surface corresponding at least to that of the panel and then placing the panel on the layer of glue.

4. A method according to any one of the preceding claims, characterized in that the glue is applied with a spatula, preferably notched.

5. A method according to any one of the preceding claims, characterized in that the polymer panel is a PVC, PET or PETg panel.

6. A method according to any one of the preceding claims, characterized in that the polymer panel has a thickness of between 1 and 6 mm, preferably between 1 and 3 mm, for example 2 mm.

7. A method according to any one of the preceding claims, characterized in that the polymer panel has a dimension greater than 2.5m, or even 3m.

8. Wall covering assembly in the form of at least one polymer panel fully bonded to a wall, characterized in that the panel is bonded with a single-component thixotropic adhesive based on silane-modified polymers also comprising mineral fillers and additives, in an amount between 100 and 500 g / m2, preferably between 250 and 320 g / m2.