AT13621U1 - A method for producing a composite body and composite bodies, which are produced according to this method - Google Patents

Abstract

The invention relates to a method for producing a composite body and composite bodies produced according to this method. A body of the composite is formed of a mineral, voided material. The material of a second part-body has a higher mechanical strength than that of the first part-body. The mineral, voided part-body is formed by stirring a flowable, self-hardening mass (2) of a mineral formulation, a foaming or blowing agent and water, and mixing this mass (2 ) is allowed to flow into a cavity, the boundary surfaces of which are at least partially formed by the surface of the body part (1) of mechanically stronger material, and allowed to cure therein.

Description

Austrian Patent Office AT 13 621 U1 2014-05-15

Description: The invention relates to a method for producing a composite body and to composite bodies which are produced according to this method.

In advantageous applications of the invention, components are produced according to the invention, which are assembled as intended to building parts such as walls, ceilings, floors, columns or beams. These components may be block-shaped (brick), flat (plates) or elongated only in one dimension (carrier).

There is a wealth of proposals to make components that are properly assembled to building parts such as walls, ceilings, floors, columns or beams as a composite body, usually the required high mechanical strength is achieved by individual body part and a good part by further body part thermal insulation.

For example, bricks are formed of composite body, wherein the harder part, the so-called brick base, a fired clay or concrete and wherein cavities are filled in this brick base by a heat-insulating material.

Often, the heat-insulating material is a foamed plastic. The plastic can be filled in liquid form in cavities of the brick base body, and harden there and also let nachschäumen, plastic and brick base stick together. But it is also possible to "finish". Press foam plastic body into cavities of the brick base body and hold it by elastic pressure and friction. Especially for reasons of building physics (diffusion openness) and for reasons of fire protection, plastic is often considered disadvantageous in this application.

The heat-insulating filling of cavities of the brick but can also be a mineral material. Typically, a granular charge of foamed siliceous material (perlite, obsidian) is mixed with water and a binder based on cement or lime, and the flowable mass thus formed is introduced into cavities of the brick base body and allowed to harden. The material is compared to plastic construction physiological and also in terms of fire protection advantageous. The disadvantage is especially the time-consuming connection process with the brick body.

In principle, the same considerations and conclusions as for bricks, apply to components that are elongated in only one dimension (carrier).

For plate-shaped components similar considerations apply. More often than in the previously discussed components one manufactures these by first making plates from the individual elements and then subsequently, sometimes even at the construction site, connects.

The object underlying the invention is to provide a composite body of at least one porous, mineral part body (- which should have a high thermal insulation value -) and at least one further part body whose material is mechanically stronger than that of the first part body , The composite body should be used, for example, as a component of a load-bearing part of the building.

Compared to known composites that meet these requirements, the newly created composite body should be better, namely faster and more flexible to produce.

To solve the problem, the invention proposes to form the porous, mineral body part of the composite body by a mineral, selbstaushär-border formulation, a foaming agent or blowing agent and water, a flowable, self-curing composition is stirred by this mass in still flowable state in a cavity whose boundary surfaces are at least partially formed by surfaces of the body part of mechanically stronger material, is filled and allowed to harden therein. Since the said flowable material is easy to prepare, is easy to handle, is readily flowable and can harden rapidly in said cavity (within a few minutes) until green strength is reached, is the manufacturing process fast and flexible.

The porous mineral body part formed in this way is very good heat resistance and emits no dangerous substances in case of fire. The individual materials required for its production are available at low cost.

For the connection of the individual partial body of the composite body, there is no need for a separate intermediate layer. If the mechanically stronger partial body likewise consists of a mineral material and has a porous surface, a good adhesion to the still more porous, mineral partial body which forms on it forms itself.

It is also possible to pretreat the surface of the mechanically stronger partial body in an advantageous manner. A very good pretreatment is to spray the surface with a jet of water, as is typically emitted from a high-pressure cleaner at, for example, five bar spray pressure, and thus superficially slightly remove material from it. While still wet, this surface should be brought into contact with said flowable mass.

Of course, a good connection between the part bodies can also be achieved by positive locking so that surfaces of a part body comprise the other part body or parts thereof.

In an advantageous embodiment, the self-curing formulation of a hydraulically setting binder, a pozzolanic setting binder and a sulfate is formed.

Preferably, the hydraulically setting binder of the formulation is formed based on a sulfate aluminate cement. It contains a sulphate component and an aluminum component and is included in the formulation at least 50% by weight.

Preferably, the foam component of the previously blended and stirred with the addition of water to a slurry formulation is mixed in a second mixing stage.

The said hydraulically setting binder causes the porous, mineral body part does not or only very slightly shrink during hardening. Too much shrinkage - which would occur in many other materials - would cause the porous, mineral sub-body to detach from the mechanically-bearing sub-body, or to break the porous, mineral sub-body.

Preferably, the proportion of the sulfate aluminate cement in the formulation is at least 60 parts by weight, in particular at least 70 parts by weight. As a result, the mechanical properties and the insulating properties of the porous, mineral part body are favorably influenced.

Preferably, the sulfate component is selected from a group comprising calcium sulfate, α- or β-hemihydrate or dihydrate of calcium sulfate, anhydrite, sodium sulfate, ferrous sulfate, magnesium sulfate and mixtures and derivatives thereof. It will thus hydrate phases are generated during the hardening of the porous, mineral body part, which undergo a phase change over time, the strength increases.

The aluminum component is preferably selected from a group comprising aluminum oxide (A1203), aluminum hydroxides, aluminum silicates, aluminates and mixtures and derivatives thereof. It can thus be positively influenced the solidification behavior and the setting time of the porous, mineral body part.

The ratio of the sulfate component to the aluminum component may be selected according to a variant of an area with a lower limit of 4:10 and an upper limit of 20: 30. It is thus achieved that the setting time of the slurry 2/9 Austrian Patent Office It does not take so long that there is a risk of the added foam collapsing and thus reducing the porosity of the porous, mineral part of the body. It is thus simplified by keeping the ratio of the two components in this area, the processing.

In particular, to further improve this behavior, the ratio of the sulfate component to the aluminum component may be selected from a range having a lower limit of 6:12 and an upper limit of 13:22, preferably a range having a lower limit of 10:18 and an upper limit of 12:24.

To improve the mechanical properties of the porous, mineral body part, the formulation may additionally contain SiO 2 particles in a proportion of not more than 10 parts by weight. However, the proportion of SiO 2 particles is preferably not more than 7.5 parts by weight, in particular not more than 7.5 parts by weight.

According to another embodiment, the formulation contains special SiO 2 particles fumed in the form of so-called silica. This is a reactive SiO 2 that can improve the fire resistance performance of the porous, mineral sub-body by reducing the energy consumption of SiO 2 to a "cooling" reaction. Has effect. In particular, carbon-free SiO 2 particles with a purity of at least 97% are used.

In one embodiment, it is provided that the SiO 2 particles have a BET surface area between 5 m 2 / g and 35 m 2 / g in order to increase the reactivity. Preferably, the SiO 2 particles have a BET surface area between 10 m 2 / g and 25 m 2 / g, in particular between 16 m 2 / g and 20 m 2 / g. Preferably, the SiO 2 particles have a particle size of at most 45 pm, wherein in particular the proportion of coarse grain is limited to a maximum of 2% and the remainder of the SiO 2 particles have a particle size of not more than 1 μm, preferably not more than 0.3 μm.

The formulation may further contain at least one so-called high-performance liquefier to influence the rheological behavior of the slurry formed from the formulation, provided that the addition of silica fumed, which also has a liquefying effect due to the spherical shape of the particles, not only for this Purpose is sufficient, the proportion is limited to a maximum of 3 percent by weight. In particular, when silica fumed is included in the formulation, the proportion of the high-performance plasticizer is limited to a maximum of 0.5 percent by weight, preferably at most 0.3 percent by weight. The high-performance liquefier is preferably a polycarboxylate ether or a derivative thereof in order to be able to reduce the water content of the slurry so that less water is available for setting and thus the desired phases are formed more reliably.

It is also possible that the formulation for stabilizing the slurry and thus for better processability of the slurry at least one thickener is added in a proportion of not more than 0.5 percent by weight. The thickener is preferably added in a proportion of not more than 0.25 percent by weight, in particular not more than 0.02 percent by weight. The thickener is preferably selected from a group comprising hydroxymethylpropylcellulose, methylhydroxyethylcellulose and mixtures and derivatives thereof, since it has been found in the context of the tests carried out for the invention that these thickeners have better properties with regard to processing, such as e.g. the rheology, the dispersion of the solids, or the water requirement and the water retention capacity. In view of the processability of the slurry, it has also been found that improvements occur when the proportion of the thickener is at most 70% of the proportion of the high-performance liquefier.

It is further possible that the formulation of fibers in a proportion of not more than 3 percent by weight, in particular not more than 1 percent by weight, preferably 0.3 percent by weight, are added in order to improve the flexural strength of the porous, mineral body part. But it can also be used to stabilize the foam component. In addition, e.g. Cellulose fibers store water, which is required in the setting process, whereby this physically "bound" " Water is better controlled with respect to the hardening of the mineral foam.

Cellulose fibers can also be used as thickeners. The fibers preferably have a maximum length of 50 mm, in particular a maximum of 30 mm, and are in particular selected from a group comprising cellulose fibers, basalt fibers, glass fibers, in particular alkali-resistant glass fibers, polypropylene fibers, and mixtures thereof.

Fibers of greater length, so for example with a length between 3 mm and 50 mm, in particular between 3 mm and 30 mm, preferably between 3 mm and 12 mm, wherein the diameter is preferably between 13 pm and 25 pm, preferably between 13 pm and 18 μm, are added mainly when bending tensile strength is to be increased.

Fibers up to a length of 0.1 mm, preferably up to 30 pm, and in particular a diameter of up to 2 pm, preferably up to 1.5 pm, are preferably added for rheological reasons.

The formulation may be added to improve the rheology at least one processing aid from a group comprising an alkali metal carbonates, alkali metal sulfates, fruit acids, for example as a retarder.

In order to reduce the proportion of sorption moisture in the porous, mineral part of the body and thus to improve the thermal insulation (A value), it can be provided that at least one hydrophobizing agent is added, in particular for mass hydrophobization of the formulation. The proportion of the hydrophobizing agent in the formulation can be up to 3 percent by weight, preferably up to 1 percent by weight.

According to another embodiment of the formulation, it may be provided that these additive-free, i. is free of fillers, so contains no non-reactive constituents, whereby the density of the porous mineral body part can be further reduced.

Preferably, the foam component is formed by a protein foam and / or a surfactant. Thus, the foaming behavior can be better controlled than in the method of direct foaming by means of a blowing agent. In particular, the pore size and the pore distribution can thus be better reproducible and influenced in a wider range. Thus, the thermal conductivity or the sound absorption capacity of the porous mineral body part can be better adjusted.

Preferably, the proportion of the foam component per m3 of slurry between 30 kg / m3 and 70 kg / m3, in particular between 40 kg / m3 and 60 kg / m3. In this area, particularly good insulating behavior of the porous, mineral part body can be achieved.

To stabilize the foam during mixing into the slurry from the formulation with water, a surfactant can be added to the foam component.

According to a preferred embodiment, the porous, mineral part body has a pore content of at least 70%, in particular between 80% and 95%. Due to this high proportion of pores not only the insulating behavior per se can be improved, but is thus also a lower density of the porous, mineral body part reachable. In this case, the pores preferably have a diameter of at most 0.5 mm, in particular not more than 0.25 mm or not more than 0.1 mm, on the one hand to achieve a positive insulating behavior and on the other hand to improve the mechanical stability of the porous, mineral body part ,

The foam component may also include air entraining agents, e.g. Alkyl polyglycol ethers, alkyl sulfates or sulfonates, i.a. to improve the stability of the foam.

According to one embodiment of the method is provided that the foam component is added to the slurry in a foam generator with water and possibly processing aids before adding to the slurry, whereby their processability, in particular the stability of the foam during mixing with the slurry, can be improved. It can be arranged in the device for foaming the foam component, a foam generator, in which a protein mixed with water with a gas, in particular air, is foamed.

The invention is illustrated by means of a drawing.

Fig. 1 shows in schematic form an exemplary arrangement for producing a composite body according to the invention in a vertical sectional view.

According to Fig. 1 is on a flat, solid base plate 3, which may be to prevent adhesion, for example, be coated with PTFE or may consist entirely of polyamide, the mechanically fixed body part 1 is placed, which, for. a perforated brick can be as a brick body. This mechanically fixed part body 1, which has approximately prismatic outer contour, has some hollow chambers which extend vertically through it and are open at the top and bottom, wherein the lower openings are closed by the base plate 3.

By a supply 4, which may be formed for example by a tube with a screw conveyor disposed therein, flowable mass 2 is filled from the slurry of the formulation described above and the foam component blended therein in the hollow chambers in the mechanically solid part body 1.

If a sufficient amount of this mass 2 is filled, the supply of further mass 2 is turned off and smoothed the surface of the filled mass by means of a straight bar, the mass 2 is withdrawn. As a result, the surface of the mass 2 is flat and flush with the top of the mechanically solid part body 1 is formed.

The mass 2 hardens in the hollow chambers to individual porous, mineral part bodies, which is connected to the mechanically solid part body 1. The rate of curing is dependent on the exact composition of the formulation in the mass 2. In particular, by the proportion of fruit acid, such as citric acid, the curing rate can be influenced. Greening is the mass 2 typically after five to ten minutes. The base plate 3 can therefore be removed after this time without the shape of the consisting of hardening mass 2 and mechanically solid part body 1 composite body still changes. 80 percent of the final strength of the resulting porous, mineral sub-body typically reached after a few hours.

The composite body thus formed may typically be a composite thermal insulation brick.

Based on the described basic principle, it is in the field of professional trade to automate individual steps of the manufacturing process or the entire process. Therefore, here is the topic "Automation of the manufacturing process " not discussed further.

By the invention can be combined in the best possible way, the high mechanical strength of a first body part with the high thermal insulation ability of a very light and thus very porous and thus forcibly mechanically very little loadable porous, mineral body part. The porous, mineral part body may be formed in the described composition with a density lower than 300 kg / m3 and with a lower thermal conductivity than 0.05 W / mK. The connection of the individual body parts is associated with no disadvantages such as loss of diffusion openness, requirement of adhesive, etc.

The inventive method is also applicable when a mechanically solid Teilköper is already installed at its place of use, and only there is to be combined with a porous, mineral part body to form a composite body. For this it is only necessary to touch the hardening mass according to FIG. 2 only at the place of use and to fill it into the corresponding cavities. Using a retardant you can see the 5/9 Austrian Patent Office AT 13 621 U1 2014-05-15

Mix the material a little earlier, at a location not too far from the place of use and, similar to ready-mixed concrete, transport it to the place of use and fill it up.

In an advantageous application, you can thus a wall which is formed by a flat frame framework and attached to both sides plasterboard, subsequently with respect to sound and heat insulation, as well as fire resistance and mechanical strength significantly improve by the cavities between the plasterboard with curable composition according to FIG. 2 fills. It is thereby formed a composite body of plasterboard, truss parts and mineral, foamed material.

In a further advantageous application, for the purpose of thermal building renovation, cavities in ceilings, especially in ceilings to the attic, to flat roofs or terraces, in retrospect filled with mass as in Fig. 2. 6.9

Claims (12)

Austrian Patent Office AT 13 621 U1 2014-05-15 Claims 1. A method for producing a composite body from at least two partial bodies, wherein a partial body is formed from a mineral, pore-containing substance and wherein the material of the second partial body has a higher one compared to that of the first partial body having mechanical strength, characterized in that the mineral, voided body part is formed by a flowable, self-curing mass (2) of a mineral formulation, a foaming or blowing agent and water is stirred and by this mass (2) into a cavity whose Limiting surfaces are at least partially formed by the surface of the body part (1) of mechanically stronger material, is allowed to flow in and allowed to harden therein. 2. The method according to claim 1, characterized in that the mineral formulation of a hydraulically setting binder, a pozzolanic setting binder and a sulfate is mixed. 3. The method according to claim 1 or claim 2, characterized in that the mass (2) coming into contact surface of the body part (1) made of mechanically stronger material in vorbenässtem state with the mass (2) is brought into contact. 4. The method according to claim 3, characterized in that of the coming into contact with the mass (2) surface of the part body (1) of mechanically stronger material, as a pretreatment for the bonding process with the mass (2), by spraying with water high spray erosion, material is removed. 5. The method according to any one of claims 1 to 4, characterized in that mass (2) is filled in order to form a thermal insulation composite brick in a cavity of a brick base body. 6. The method according to any one of claims 1 to 4, characterized in that mass (2) is filled in a cavity in a building surface. 7. The method according to claim 6, characterized in that mass (2) is filled into the cavity between two arranged on both sides of a flat frame plasterboard. 8. composite of two interconnected part bodies, wherein a part body of a mineral, pore-containing substance is formed and wherein the material of the second part body relative to that of the first part body has a higher mechanical strength, characterized in that the mineral, pores having part body formed by hardening a flowable, self-hardening mass (2) of a mineral formulation, a foaming agent or blowing agent and water in a cavity whose boundary surfaces are at least partially formed by the surface of the part body (1) of mechanically stronger material. 9. A composite according to claim 8, characterized in that the mineral formulation consists of a hydraulically setting binder, a pozzolanic setting binder and a sulfate. 10. A composite according to claim 8 or 9, characterized in that it is a component which is intended together with similar components to building parts such as walls, ceilings, floors, columns or beams assembled. 11. A composite body according to claim 10, characterized in that it is a composite thermal insulation brick. 7/9 Austrian Patent Office AT 13 621 U1 2014-05-15 12. A composite according to claim 11, characterized in that it is a sandwich plate, wherein the middle layer is formed by the mineral, pore-containing substance. For this purpose 1 sheet drawings 8/9