CN103228850A - 板形建筑元件 - Google Patents
板形建筑元件 Download PDFInfo
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- CN103228850A CN103228850A CN2011800570419A CN201180057041A CN103228850A CN 103228850 A CN103228850 A CN 103228850A CN 2011800570419 A CN2011800570419 A CN 2011800570419A CN 201180057041 A CN201180057041 A CN 201180057041A CN 103228850 A CN103228850 A CN 103228850A
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- Prior art keywords
- cementing agent
- constracture unit
- polymer
- alternatively
- reinforcing rib
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Abstract
本发明涉及通过包含一种或多种无机物粘合剂和/或一种或多种聚合物粘合剂,以及一种或多种可选的填料、一种或多种可选的混合物或一种或多种添加剂的粘结剂,通过将加强筋附连到绝缘板上而获得的建筑元件,所述加强筋部分地而并非全部地嵌入在所述粘结剂中。
Description
技术领域
本发明涉及建筑元件,并且还涉及其用于生产模板(formwork)和建筑结构的用途。
背景技术
在建筑部分中,模板长期用于安装(erection)建筑结构。一般地,使用由木材或复合材料制成的模板墙。模板通常设立在建筑工地上,并且填充有建筑材料,例如混凝土。在混凝土凝固之后,移除模板,并且安装未衬砌的、未精加工的墙壁或地板或天花板。与模板相关的缺点是需要获得(以及为建筑工地施工期提供)并未作为建筑结构的一部分结束的另外的辅助设备。此外,提供模板和使用粘结剂,例如滑模油(forming oil)对模板进行事前预处理,以及拆卸并且随后清洁模板,都与大量的成本和不便相关联。
因此需要更有效、更灵活和更通用的方法来生产建筑结构,更具体地使用预制部件来生产建筑结构。为此目的提出的是,例如由钢格构构件(steel latticework)制造的笼状物,其有可能具有墙壁的形状和尺寸,其被包围的内部(enveloped interior)填充有绝缘材料,例如Styropore颗粒或聚氨酯泡沫。这类钢格板可以经由钢格彼此结合,或由框架悬挂。能够给予(render)表面和空隙,并且使用空中浇筑混凝土或灰浆填充。然而,这类部件的静态性能受到限制。尽管具体的缺点在于尽管广泛地使用绝缘材料,钢格板的绝缘特性是令人不满意的,因为钢格板的钢将内部结合到墙壁的外部,并且起冷桥的作用。
类似地,令人不满意的绝缘特性是由于建筑元件,其中用于外壁或内壁绝缘作用的绝缘板的建筑元件用作模板壁,通过金属隔片紧固。这些隔片穿过绝缘板。通常需要超过十个隔片/平方米。然后,以这种方式预制的建筑元件,例如用混凝土填充,从而制成在内部和外部被绝缘板绝缘的混凝土墙壁。其结果是,不需要使混凝土墙壁与模板分离所必须的成本和复杂性。然而,隔片起冷桥的作用。此外,隔片可以不利地影响墙壁的静态特性。
发明内容
针对这个背景,本发明的目的是提供装置,使用所述装置通常用于绝缘建筑结构的绝缘板可以用作模板,本发明在于该模板可以保留在建筑结构中,并且因此获得的建筑结构可以具有改善的热绝缘性。另一个目的是,这些装置可以积极地影响建筑结构的静态特性,并且可以在能够使用的形状、重量或材料方面,灵活地适应于建筑结构的任何设计。本发明的目的为还能够使部件灵活地适应于具体的应用地点的要求,像例如耐水性、水蒸气渗透性或机械特性。本发明的目的还有,可以制造低重量,即具有低密度,的建筑元件,从而允许建筑元件容易被个人运送,甚至不需要辅助装置,例如起重机。
本发明提供通过用粘结剂将加强筋(reinforcement)紧固到绝缘板上来获得的建筑元件,粘结剂包含一种或多种无机物粘合剂和/或一种或多种聚合物粘合剂,和可选地一种或多种填料,可选地一种或多种佐剂,以及可选地一种或多种添加剂,并且加强筋部分地但并非完全地嵌入粘结剂中。
绝缘板通常基于有机或无机、天然或合成的绝缘材料。合成绝缘材料的实例是塑料材料,例如聚苯乙烯,更具体地为膨胀型或挤出型聚苯乙烯,或聚氨酯,更具体地为聚氨酯泡沫,矿物材料,更具体地为矿物纤维、矿棉、或矿物泡沫、或沥青。
天然无机绝缘材料的实例是基于石膏或基于水泥的材料。
天然有机绝缘材料的实例是木材,具体地为木板、纸板、胶合板、木纤维板、层板、OSB(定向刨花板)、草或茎秆的形式。
通常使用有机或无机物粘合剂,结合纤维形式的绝缘材料,例如矿棉、木纤维、刨花、草或茎秆,并且使其变成面板形式。尽管,绝缘板的制造是专业人员已知的。
绝缘板拥有低导热性,因此适合热绝缘,例如以建筑结构的情况作为举例。此外,绝缘板具有隔音作用。绝缘板的导热性优选地为0.001至60W/mk,更优选地为0.002至5W/mk,并且最优选地为0.004至3W/mk(对于塑料材料,根据DIN18159P.1测定;对于矿物材料,根据DIN18165测定;对于沥青,根据DIN52128测定;对于基于石膏的系统,根据DIN18180测定;对于基于水泥的系统,根据18550P3或DIN1045测定;对于木材,根据DIN68705测定)。
绝缘板的尺寸可以是任意的。绝缘板通常具有20至150cm的宽度,以及50至500cm的长度。绝缘板的厚度优选地为1至50cm,更优选地为3至30cm,最优选地为5至20cm。绝缘板的密度优选地为5至2500kg/m3,更优选地为10至100kg/m3,并且最优选地为15至50kg/m3。因此,绝缘材料优选地具有低密度。
在其顶面和/或底面,可以用外部材料,像例如用卡片、纸、铝箔、沥青、硅酸盐乳化漆或泡罩膜(blister film)来排列绝缘板。此类板的一个实例是石膏板。
还有可能处理两个或更多绝缘板,从而形成层压板。层压板通常包括平坦地固定在彼此上面并且紧固到彼此上的两个或更多绝缘板。层压板中的单个绝缘板通常通过粘结结合来紧固,但是可替代地,还可以通过螺旋或其他紧固方法来紧固。层压板优选地包括一个或多个石膏板面板以及基于选自包括以下的组的绝缘材料的一个或多个绝缘板:膨胀型聚苯乙烯、挤出型聚苯乙烯和矿棉;或者一个或多个聚苯乙烯面板和基于来自包括以下的组的绝缘材料的一个或多个绝缘板:刨花和矿棉。
加强筋通常基于有机材料,例如塑料,或基于无机材料,例如金属,更具体地为钢,或者基于无机纤维,更具体地为碳纤维或玻璃纤维。
金属优选地以金属丝、格构垫(lattice mat)或膨胀型格构的形式存在,其依次成形从而形成三维轮廓,即,并非完全片状的轮廓。金属优选地具有波状线形或锯齿形轮廓。
金属丝优选地具有0.1至30mm的直径,更优选地为1至10mm。例如,可以通过结合金属丝和/或金属丝网(mesh)来制造格构垫。
无机纤维优选处于网状或机织织物的形式。
塑料能够以例如,做成波状线形或锯齿形轮廓形状的格构垫或膨胀型格构的形式,或以网状或机织织物的形式存在。因此,金属丝、格构垫或膨胀型格构通常并且排他性地以基本上平面材料,例如线形金属丝或平面格构垫或平面膨胀型格构构成。
合适的无机物粘合剂的实例是水泥,更具体地是波特兰水泥、铝酸盐水泥,更具体地是硫铝酸钙水泥、粗面凝灰岩水泥、矿渣水泥、镁氧水泥、磷酸盐水泥或高炉矿碴水泥,还有混合水泥、填料水泥、飞灰、微米硅、炉渣砂、熟石灰、白色熟石灰、氧化钙(生石灰)和石膏。优选波特兰水泥、铝酸盐水泥和矿渣水泥,还有混合水泥、填料水泥、熟石灰、白色熟石灰或石膏。
同样优选包含至少两种无机物粘合剂的粘结剂。在一个特别优选的实施例中,粘结剂包含铝酸盐水泥和一种或多种另外的无机物粘合剂。基于其他无机物粘合剂的重量份数,优选地使用0.01至99份重量,更优选地0.05至10份重量,以及最优选地0.1至5份重量的铝酸盐水泥。使用铝酸盐水泥导致特别快速地干燥粘结剂以及与聚合物粘合剂结合,从而有效地将粘结剂粘附到绝缘板以及粘附到加强筋上(尤其是金属)。
在粘结剂的另一个优选实施例中,使用的粘合剂单独地是无机物粘合剂,换句话说,没有聚合物粘合剂。在粘结剂的同样优选的实施例中,使用的粘合剂单独地是聚合物粘合剂,即没有无机物粘合剂。然而,特别优选地,粘结剂包含一种或多种无机物粘合剂和一种或多种聚合物粘合剂。
合适聚合物粘合剂的实例是聚氨酯、聚酯、乙烯基酯、聚环氧化物或聚酰胺,或优选地,基于烯属不饱和单体的聚合物。
基于烯属不饱和单体的聚合物是基于,例如选自包括以下的组的一种或多种烯属不饱和单体:乙烯基酯、(甲基)丙烯酸酯、乙烯基芳烃、烯烃、1,3-二烯、和乙烯卤化物,以及可选地与其可共聚的另外的单体。
合适乙烯基酯的实例是具有1至15个C原子的羧酸的乙烯基酯。优选乙酸乙烯基酯、丙酸乙烯基酯、丁酸乙烯基酯、2-乙基己酸乙烯基酯、月桂酸乙烯基酯、乙酸1-甲基乙烯基酯、新戊酸乙烯基酯,和具有9至11个C原子的α分支单羧酸的乙烯基酯,例如VeoVa9R或VeoVa10R(Resolution的商品名)。特别优选乙酸乙烯基酯。
来自丙烯酸酯或甲基丙烯酸酯基团的合适单体的实例是具有1至15个C原子的未分支或分支醇的酯。优选的甲基丙烯酸酯或丙烯酸酯是甲基丙烯酸酯、甲基丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸乙酯、丙烯酸丙酯、甲基丙烯酸丙酯、丙烯酸正丁基酯、甲基丙烯酸正丁基酯、丙烯酸叔丁基酯、甲基丙烯酸叔丁基酯、以及丙烯酸2-乙基己基酯。特别优选丙烯酸甲酯、甲基丙烯酸甲酯、丙烯酸正丁基酯、丙烯酸叔丁基酯、和丙烯酸2-乙基己基酯。
优选的乙烯基芳烃是苯乙烯、甲基苯乙烯、和乙烯基甲苯。优选的乙烯卤化物是氯乙烯。优选的烯烃是乙烯和丙烯,并且优选的二烯是1,3-丁二烯和异戊二烯。
可选地,基于单体混合物的总重量,还有可能共聚合0至10wt%的辅助单体。优选使用0.1至5wt%的辅助单体。辅助单体的实例是烯属不饱和单羧酸和二羧酸,优选丙烯酸、甲基丙烯酸、富马酸和马来酸;烯属不饱和甲酰胺和腈,优选丙烯酰胺和丙烯腈;富马酸和马来酸的单酯和二酯,例如二乙基酯和二异丙基酯,还有马来酸酐;烯属不饱和磺酸和/或其盐,优选乙烯基磺酸和2-丙烯酰胺基-2-甲基丙磺酸。另外的实例是预先交联的共聚单体,例如聚烯属不饱和共聚单体,例如邻苯二甲酸二烯丙基酯、己二酸二乙烯基酯、马来酸二烯丙基酯、甲基丙烯酸烯丙基酯、或氰尿酸三烯丙基酯,或后交联的共聚单体,例如丙烯酰胺乙醇酸(AGA)、甲基丙烯酰胺乙醇酸甲酯(MAGME)、N-羟甲基丙烯酰胺(NMA)、N-羟甲基甲基丙烯酰胺、N-羟甲基烯丙基氨基甲酸酯、烷基醚,例如N-羟甲基丙烯酰胺的异丁氧基醚或酯、N-羟甲基甲基丙烯酰胺的异丁氧基醚或酯、以及N-羟甲基烯丙基氨基甲酸酯的异丁氧基醚或酯。同样适合的是环氧化物官能化的共聚单体,例如甲基丙烯酸缩水甘油酯和丙烯酸缩水甘油酯。另外的实例是硅官能化的共聚单体,例如丙烯酰基氧基丙基三(烷氧基)-硅烷和甲基丙烯酰基氧基丙基三(烷氧基)-硅烷、乙烯基三烷氧基硅烷和乙烯基甲基二烷氧基硅烷,其中可以存在的烷氧基基团的实例为乙氧基和乙氧基丙二醇醚基团。还可以提到具有羟基或CO基团的单体,实例是甲基丙烯酸酯和丙烯酸羟基烷基酯,例如羟基乙基、羟基丙基、或羟基丁基的丙烯酸酯或甲基丙烯酸酯,还有化合物,例如二丙酮丙烯酰胺和乙酰基乙酰氧基乙基的丙烯酸酯或甲基丙烯酸酯。
优选选自包括以下的组的一种或多种聚合物:包含来自包括乙烯基酯、烯烃、乙烯基芳烃、乙烯基卤化物、丙烯酸酯、甲基丙烯酸酯、富马酸和/或马来酸单酯或二酯的组的一种或多种单体单元的乙烯基酯均聚物、乙烯基酯共聚物;包含来自包括甲基丙烯酸酯、丙烯酸酯、烯烃、乙烯基芳烃、乙烯基卤化物、富马酸和/或马来酸单酯或二酯的组的一种或多种单体单元的(甲基)丙烯酸酯均聚物、(甲基)丙烯酸酯共聚物;二烯的均聚物或共聚物,例如丁二烯或异戊二烯,还有烯烃的均聚物或共聚物,例如乙烯或丙烯,二烯有可能,例如与苯乙烯、与(甲基)丙烯酸酯,或与富马酸或马来酸酯共聚合;乙烯基芳烃的均聚物或共聚物,例如苯乙烯、甲基苯乙烯和乙烯基甲苯;以及乙烯基卤化物化合物的均聚物或共聚物,例如氯乙烯,这些聚合物还有可能包含辅助单体。
特别优选具有1至50wt%乙烯的一种或多种乙烯基酯的共聚物;具有1至50wt%乙烯和1至50wt%来自在羧酸基团中具有1至12个C原子的乙烯基酯(例如丙酸乙烯基酯、月桂酸乙烯基酯,具有9至13个C原子的α-分支羧酸的乙烯基酯,例如VeoVa9、VeoVa10和VeoVall)的组的一种或多种另外的共聚单体的乙酸乙烯酯的共聚物;一种或多种乙烯基酯、1至50wt%乙烯、并且优选1至60wt%具有1至15个C原子的未分支或分支醇的(甲基)丙烯酸酯,更具体地丙烯酸正丁基酯或丙烯酸2-乙基己基酯的共聚物;以及具有30至75wt%乙酸乙烯基酯、1至30wt%月桂酸乙烯基酯或具有9至11个C原子的α-分支羧酸的乙烯基酯,还有1至30wt%具有1至15个C原子的未分支或分支醇的(甲基)丙烯酸酯,更具体地丙烯酸正丁基酯或丙烯酸2-乙基己基酯的共聚物,其还可以包含1至40wt%的乙烯;具有一种或多种乙烯基酯、1至50wt%乙烯,和1至60wt%氯乙烯的共聚物;聚合物还可以包含所述量的所述辅助单体,并且在每种情况下,以wt%表示的数字合计为100wt%。
特别优选还有(甲基)丙烯酸酯聚合物,例如丙烯酸正丁基酯或丙烯酸2-乙基己基酯的共聚物,或甲基丙烯酸甲酯与丙烯酸正丁酯和/或丙烯酸2-乙基己基酯的共聚物;具有来自丙烯酸甲酯、丙烯酸乙酯、丙烯酸丙酯、丙烯酸正丁酯和丙烯酸2-乙基己基酯的组中的一种或多种单体的苯乙烯-丙烯酸酯共聚物;具有来自丙烯酸甲酯、丙烯酸乙酯、丙烯酸丙酯、丙烯酸正丁基酯、丙烯酸2-乙基己基酯和可选地乙烯的组中的一种或多种单体的乙酸乙烯酯-丙烯酸酯共聚物;以及苯乙烯-1,3-丁二烯共聚物;这些聚合物还可以包含所述量的辅助单体,并且在每种情况下以wt%表示的数字合计为100wt%。
用于氯乙烯共聚物的特别优选的共聚单体的实例是α-烯烃,例如乙烯或丙烯,和/或乙烯基酯,例如乙酸乙烯基酯,和/或具有1至15个C原子的醇的丙烯酸酯和/或甲基丙烯酸酯,例如丙烯酸甲酯、甲基丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸乙酯、丙烯酸丙酯、甲基丙烯酸丙酯、丙烯酸正丁基酯、丙烯酸叔丁基酯、甲基丙烯酸正丁基酯、甲基丙烯酸叔丁基酯、丙烯酸2-乙基己基酯,和/或富马酸和/或马来酸单酯或二酯,例如马来酸和/或富马酸的二甲基酯、甲基-叔丁基酯、二-正丁基酯、二-叔丁基酯和二乙基酯。
最优选具有乙酸乙烯基酯和5至50wt%乙烯的共聚物;或具有乙酸乙烯酯、1至50wt%乙烯、和1至50wt%具有9至11个C原子的α-分支单羧酸的乙烯基酯的共聚物;或具有30至75wt%乙酸乙烯基酯、1至30wt%月桂酸乙烯基酯或具有9至11个C原子的α-分支羧酸的乙烯基酯,还有1至30wt%具有1至15个C原子的未分支或分支醇的(甲基)丙烯酸酯的共聚物,其还包含1至40wt%乙烯;或具有乙酸乙烯基酯、5至50wt%乙烯、和1至60wt%氯乙烯的共聚物。
最优选的共聚物还是氯乙烯-乙烯共聚物,其包含60至98wt%氯乙烯单元和1至40wt%乙烯单元,基于共聚物的总重量以wt%表示数字,并且在每种情况下合计为100wt%。由EP0149098A2可知这些类型的氯乙烯-乙烯共聚物。
进行单体选择以及共聚单体的重量分数的选择,从而导致-50℃至+30℃的玻璃转化温度Tg,优选-40℃至+10℃,更优选-30℃至0℃。通过差示扫描量热法(DSC)以已知的方式能够测定聚合物的玻璃转化温度Tg。还可以通过Fox方程预先近似地计算Tg。根据Fox T.G.,Bull.Am.Physics Soc.1,3,126页(1956):1/Tg=x1/Tg1+x2/Tg2+…+xn/Tgn,其中xn表示单体n的质量分数(wt%/100),并且Tgn是单体n的均聚物的玻璃转化温度(以开尔文为单位)。在Polymer Handbook,第二版,J.Wiley&Sons,纽约(1975)中,列出了均聚物的Tg值。
可以通过本体或溶液聚合工艺或优选地,乳液或悬液聚合工艺,来制备基于烯属不饱和单体的聚合物。通常在例如DE-A102008043988中描述的水性介质中进行乳液或悬液聚合作用。在这种情况下,以水性分散体的形式获得聚合物。为了聚合,有可能使用如DE-A102008043988中所描述的一般性保护胶体和/或乳化剂。保护性胶体可以是阴离子型,或优选地是阳离子型,或更优选地是非离子型。同样优选阳离子型和非离子型保护性胶体的组合。优选的非离子型保护性胶体是聚乙烯醇。优选的阳离子型保护性胶体是带有一个或多个阳离子电荷的聚合物,例如,如E.W.Flick,Water Soluble Resins-an Industrial Guide,Noyes Publications,Park Ridge(派克里奇),N.J.,1991中所描述的。优选的保护性胶体是具有80至100mol%水解度的部分或完全水解的聚乙烯醇,更具体地是具有80至94mol%水解度,以及在4%强度水溶液中粘度为1至30mPas(20℃下方法,DIN53015)的部分水解的聚乙烯醇。所述的保护性胶体是通过技术人员已知的方法获得的,并且对于聚合作用,通常添加基于单体总重量,总计1至20wt%的量。
如DE-A102008043988所描述,可以将处于水分散体形式的聚合物转化为可以再分散于水中的相应粉末。在这种情况下,通常,以基于分散体的聚合物组成,3至30wt%,优选5至20wt%的总量使用干燥助剂。上述聚乙烯醇优选作为干燥助剂。
合适填料的实例是硅砂、石英粉、石灰岩粉、碳酸钙、白云石、粘土、白垩、白色熟石灰、滑石或云母、粒状橡胶,或硬性填料,例如硅酸铝、金刚砂、玄武岩、碳化物,例如碳化硅或碳化钛,或凝硬性(pozzolanically)反应填料,例如飞灰、偏高领土、微米硅、和硅藻土。优选的填充剂是硅砂、石英粉、石灰岩粉、碳酸钙、碳酸钙镁(白云石)、白垩、或白色熟石灰。
还优选使用轻质填料。轻质填料是用于具有低本体密度,通常小于500g/l的填料的术语。在合成或天然基础(basis)上的典型轻质填料是物质,例如空心玻璃微珠粒、聚合物,例如聚苯乙烯珠粒、铝硅酸盐、氧化硅、氧化硅铝、水化硅酸钙、二氧化硅、硅酸铝、硅酸镁、水化硅酸铝、硅酸钙铝、水化硅酸钙、硅酸铝铁镁、偏硅酸钙和/或火山熔渣。轻质填料的形式不受限制,并且可以特别地具有特征为球形、板形、小棒形和/或薄层结构。优选的轻质填料是珍珠岩、Cellite、Cabosil、Circosil、Eurocell、Feillite、Promaxon、Vermex和/或硅灰石,还有聚苯乙烯。
还有可能使用所述填料的任何希望的混合物。优选的混合物包含至少两种不同的填料。优选的混合物包含一种或多种碳酸盐填料和一种或多种其他填料。碳酸盐填料优选地选自包括以下的组:碳酸钙、白垩、白云石、和石灰石。优选的混合物包含基于全部使用的填料的总重量,优选5至60wt%,更优选10至50wt%,并且最优选20至50wt%的碳酸盐填料。使用碳酸盐填料可以增加粘结剂的机械坚固性。
填料具有优选0.1μm至4mm,更优选1μm至2mm,并且最优选1μm至1mm的直径。在一个特别优选的实施例中,填料不包含砂砾(gravel)。砂砾通常具有>2mm的直径。
用于粘结剂的优选配制品包含优选0.1至95wt%,更优选0.1至30wt%,并且最优选0.5至10wt%聚合物粘合剂;优选1至95wt%,更优选5至80wt%,最优选20至50wt%无机物粘合剂;优选5至95wt%,更优选30至85wt%,并且最优选49至75wt%填料;以wt%表示的数字是基于粘结剂的干重,并且加起来合计100wt%。
在一个优选的实施例中,粘结剂包含来自包含以下的组的一种或多种增塑剂作为一种添加剂:酪蛋白、木素磺酸盐、三聚氰胺和聚碳酸酯。在流平(leveling)剂、液化剂或流动控制剂方面,增塑剂也是已知的。基于粘结剂的干重,在粘结剂中增塑剂优选地以0.01至1wt%的量存在。这些类型的粘结剂还称为找平灰浆(leveling mortar)。找平灰浆导致其中加强筋特别牢固地结合到绝缘板上的建筑元件。
在另一个优选的实施例中,粘结剂包含来自包括以下的组的一种或多种增稠剂作为一种添加剂:多糖,例如纤维素醚和改性纤维素醚、淀粉醚、瓜尔豆胶、黄原胶、聚羧酸,例如聚丙烯酸及其偏酯,还有可以可选地被乙酰化或疏水地改性的聚乙烯醇、酪蛋白和相关增稠剂。基于粘结剂的干重,在粘结剂中增稠剂优选以0.01至1wt%存在。该类型的粘结剂也被称为砌筑砂浆。基于砌筑砂浆的干重,砌筑砂浆优选地包含<0.005wt%增塑剂。
粘结剂的一种常规佐剂还包含一种或多种凝结加速剂,像例如有机酸或无机酸的碱金属盐或碱土金属盐或铝盐。优选的凝结加速剂是铝盐、铝酸盐、碱金属硅酸盐,例如水玻璃,例如碱金属碳酸盐或氢氧化钾。特别优选的凝结加速剂是硫酸铝、碱金属铝酸盐,例如铝酸钾、氢氧化铝、碳酸钾,或硫铝酸盐,例如硫铝酸钙。基于粘结剂的干重,在粘结剂中凝结加速剂优选以0至2wt%,更优选以0.1至1wt%,并且最优选以0.1至0.5wt%存在。
用于粘结剂的常规添加剂是防水剂,例如脂肪酸或其衍生物,例如酯或硅酮。其他常规添加剂是阻滞剂,例如羟基羧酸,或二羧酸或其盐、糖类、草酸、琥珀酸、酒石酸、葡糖酸、柠檬酸、蔗糖、葡萄糖、果糖、山梨糖醇、和季戊四醇。其他常见添加剂是交联剂,例如金属氧化物或半金属氧化物,更具体地为硼酸或聚硼酸盐,或二醛,例如戊二醛;另外的添加剂是纤维,例如Kevlar、粘胶纤维、聚酰胺纤维、聚酯纤维、聚丙烯腈纤维、Dralon纤维、聚乙烯纤维、聚丙烯纤维、聚乙烯醇纤维、芳香族聚酰胺纤维或碳纤维。还可以提到以下各项:防腐剂、成膜助剂、分散剂、泡沫稳定剂、消泡剂和阻燃剂(例如,氢氧化铝)。
一般而言,在每种情况下基于粘结剂的干重,在粘结剂中添加剂的份数总计为0至20wt%,优选0.1至15wt%,并且更优选0.1至10wt%。
一般而言,在应用粘结剂之前,将水添加到粘结剂中。基于粘结剂的干重,以此方式获得的水性粘结剂包含优选10至90wt%,并且更优选15至50wt%的水。
粘结剂优选以干混物(dry mix)的形式预先混合。除了水之外,干混物优选地包含所讨论的配方的所有成分。因此粘结剂优选地是单组分系统。
粘结剂还可以用作二组分系统。在二组分系统中,第一组分包含一种或多种铝酸盐水泥、一种或多种聚合物粘合剂、一种或多种填料、可选地一种或多种添加剂、以及可选地一种或多种添加剂,还有水。第二组分相应于第一组分,其差异在于代替铝酸盐水泥,存在一种或多种其他无机物粘合剂。第一组分和第二组分的单个成分的重量份数符合上述粘结剂配方的数字。在每种情况下基于其干重,以1:3至3:1的比率使用第一组分和第二组分。能够在通常的混合设备中混合第一和第二组分。在两种组分混合之后,在几秒至几分钟之后粘结剂凝固。还可以通过使用凝结加速剂来控制粘结剂的凝固。当要求粘结剂的快速凝结或干燥时间,还有连续的但是可间断的操作方案时,在建筑元件的工业生产中,二组分系统具有并非最不重要的优点。
当使用找平灰浆(即包含增塑剂的粘结剂)时,二组分系统是特别优选的。
粘结剂的制备并不依赖任何具体的程序或混合装置。粘结剂是通过在常规粉末混合设备中(例如通过泥浆混合机、混凝土混合机或石膏机器或搅拌器),通过混合和均质化配方的单个成分来获得的。
聚合物粘合剂能够例如以市售的这种类型的做好的分散粘结剂的形式使用。基于烯属不饱和单体的聚合物优选地以水分散体的形式使用,或者更优选地以可再分散于水中的粉末形式使用。分散体具有优选1至80wt%,更优选5至70wt%,并且最优选10至60wt%的固体含量。
为了将加强筋紧固到绝缘板上,可以首先将粘结剂,然后将加强筋施加到绝缘板上。可替代地,还可以首先将加强筋布置到绝缘板上,之后可以施加粘结剂。以这些方式可以获得建筑元件。
在此有可能为绝缘板一侧的整个表面提供粘结剂层。然而,优选地粘结剂以粘结剂轨道(track)或粘结剂点(dot)的形式施加到绝缘板的一侧上。粘结剂还可以引入到绝缘板的凹陷中。可以通过从绝缘板中移除材料,例如通过碾磨出材料或切掉材料,或者通过使用其中最上层并未完全覆盖下面的一层或下面的多层的层压板,来制造凹陷,使得层压板包含凹陷。
将粘结剂点或粘结剂轨道施加到绝缘板上,产生具有相对低重量的建筑元件,从而有助于处理建筑元件。
粘结剂(粘结剂层)的施加厚度优选地为2至80mm,并且更优选地为3至50mm。粘结剂点优选地是近似圆形的,并且具有优选地20至200mm直径。粘结剂轨道可以具有任何希望的长度,这取决于绝缘板。粘结剂轨道的宽度优选地为20至200mm。粘结剂点和/或粘结剂轨道的这些施加厚度和尺寸,与建筑元件和/或模板的低重量结合,有利于建筑元件和/或模板的机械稳定性和坚固性。
加强筋从粘结剂或粘结剂层突出,优选5至500mm,更优选50至300mm,并且最优选100至200mm。换句话说,加强筋部分地但并非完全地嵌入粘结剂中。当建筑元件用于制造模板时,从粘结剂中突出的加强筋可以用于固定不同建筑元件。
将粘结剂施加到绝缘板上并不依赖任何具体的程序,并且可以例如手工地或例如使用喷雾机机械地实现。
粘结剂固化之后,和/或粘结剂由于可能的干燥凝固之后,加强筋牢固地连接到绝缘板上。
具体实施方式
建筑元件的优选实施例显示在图1中。图中描绘的两个建筑元件各自由元件(1)、(2)和(3)组成。在图1中,具有不同厚度并且基于不同材料的两个绝缘板(1)各自具有粘结剂的施加层(2),在每种情况下嵌入其中作为加强筋(3)的是具有锯齿形轮廓的金属丝。因此加强筋(3)部分地,但并非完全地嵌入到粘结剂层(2)中,因此从粘结剂层(2)中突出。图1是穿过建筑元件的加强筋(3)的横截面。
在建筑元件的一个具体实施例中,一种或多种涂料可以施加到建筑元件上,像例如一种或多种抹灰(render)或油漆,作为实例。一般而言,涂料施加到建筑元件的带有加强筋的侧面相对的绝缘板的侧面上。有可能首先将加强筋施加到绝缘板上,然后施加一种或多种涂料。可替代地,还有可能首先将一种或多种涂料施加到绝缘板上,然后施加加强筋。
涂料的实施例基本上是任意的,并且通过关于建筑元件的需要或者通过有待由其制造的建筑结构进行指导,并且可以适应,例如对于外部或内部墙壁的具体要求。这些要求是,例如压缩强度、毛细管吸水、抗冲击性或水蒸气渗透性。在能够用来制造涂料的涂料材料中,可以包括上述粘结剂。在工业制造建筑元件的情况下,即在大规模制造建筑元件的情况下,优选地以上述二组分系统的形式使用涂层材料。
还有可能将装置,例如气体、水或废水线路、电线或的中空管用于建筑元件。
本发明另外提供的是使用本发明的建筑元件来制造模板。模板是通过以这种方式相对于彼此布置建筑元件而获得的,即建筑元件的具有加强筋的侧面彼此相对,并且建筑元件通过并非完全嵌入粘结剂中的加强筋的部分彼此连接。以此方式,在建筑元件之间制造空腔。
在一个优选的实施例中,建筑元件以这种方式相对于彼此布置,即形成波形线或锯齿形式样的彼此相对的加强筋的加强筋(轮廓)彼此靠近或,优选地重叠。以此方式,加强筋上面的建筑元件能够以特别有利的方式结合到彼此上。如果轮廓重叠,则形成插头(plug)元件,例如金属棒,优选大致线性的金属棒能够插入其中的缝隙。金属棒的直径优选地为1至50mm,更优选地为1.5至20mm。金属棒的长度可以变化,但是通常由绝缘板的尺寸来指导。以此方式,建筑元件能够以从技术观点看有效的,并且特别简单的方式彼此结合。模板的这种实施例的一个优选变体显示在图2中。上面较早描述的图1中的两个建筑元件,在图2中变为一定程度地朝向彼此使得两个建筑元件的加强筋(3)重叠,并且以此方式形成金属棒(4)作为插头元件引入到其每个中的缝隙,因此两个建筑元件彼此连接。图2是穿过模板的加强筋(3)的横截面。
可替代地,不同建筑元件的加强筋还能够以不同方式彼此互连。在另外的变体中,还可以通过舌榫系统进行建筑元件的连接。
在另外的替代性程序中,通过至少一个加强筋通过结合至少两个绝缘板来获得模板,其中至少一个加强筋以加强筋部分地但并非完全地嵌入粘结剂中的方式,用粘结剂紧固到不同的绝缘板上。以此方式,从绝缘板开始,以一个步骤获得模板。当使用纤维形式的塑料材料或绝缘材料作为加强筋时,该程序是特别优选的。这些类型的绝缘材料导致可收缩或可折叠的模板,然后,在稍后的时间点能够再次去折叠,像例如其在建筑工地的使用。折叠起来的建筑元件能够更容易并且更有效地储存和运输。模板能够以预制形式供应到建筑工地中,或者能够在建筑工地上原位制造。
为了制造建筑结构,要填充建筑元件之间模板中存在的空腔。可以使用任何需要的填充材料进行填充,例如混凝土,包括轻质混凝土,或泥浆,可选地与轻质填料的组合。使用的其他填充材料可以包含一种或多种轻质填料。适于这个目的的轻质填料的实例是上述轻质填料。优选作为填充材料的轻质填料是膨胀型黏土、膨胀型玻璃、珍珠岩、黏土、肥土、吹入(blow-in)填料,例如纤维素纤维或纸屑,或聚合物结合的黏土或肥土。这些轻质填料可以是结合或未结合的。轻质填料更具体地用于建筑结构的内墙。
填充材料的本体密度通常为10至2600kg/cm3,优选地为500至2600kg/cm3,更优选地为1500至2300kg/cm3,并且最优选地为1800至2200kg/cm3。轻质填料的本体密度通常为10至2500kg/cm3,并且更优选地为100至1800kg/cm3。轻质填料导致具有特别低的重量和特别高的热绝缘性的建筑结构。
建筑元件和建筑结构可以提供有低重量/单位面积,例如优选地为5至100kg/m2,更优选地为5至50kg/m2,并且最优选地为10至25kg/m2。
模板的整个空腔能够以一个步骤填充上填充材料。可替代地空腔还能够以多个步骤填充上填充材料。在替代性程序的情况下,当使用例如混凝土(包括轻质混凝土或泥浆)作为填充材料时,模板暴露于较低的静水荷载(如果添加另外的填充材料,则仅当之前添加的填充材料已经干燥或凝结时才进行)。
引入的填充材料还改善模板和/或建筑结构的稳定性和静态特性。为了进一步改善稳定性,可以将建筑元件或模板紧固到基板上,像例如刮板(screed)。适合这个目的的是常规的泡沫粘结剂或泥浆,更具体地为找平灰浆。以此方式,还有可能补偿底板的任何不平性。为了侧向紧固模板和/或为了防止模板滑动,可以将模板放置在地面上制造的凹陷中,或者可以通过侧向安装的支柱或板来支持。
建筑结构的实例是墙壁、地板、天花板或整个建筑结构。更大的建筑结构可以通过彼此并排放置多个模板元件并且用填充材料将其填充而获得。
令人惊讶地,建筑元件和模板对于机械负载是非常稳定的,所以模板不会被为了制造建筑结构的目的而引入填充材料所破坏。可以通过无机物粘合剂和聚合物粘合剂(更具体地为基于烯属不饱和单体的聚合物)的组合,来加强建筑元件的稳定性。
从本发明的建筑元件的低重量和简单操作上看,可以由单个人装配建筑结构,甚至不需要使用辅助设备,例如起重机。此外,本发明的建筑元件能够以特别时间高效的和成本高效的方式,甚至通过工业制造方法来获得。对于出色的绝缘特性,本发明的建筑结构是显著的。用于制造模板的绝缘板保留在建筑结构中。通过相应地结合加强筋,建筑结构的静态特性能够适应具体的技术性的建筑需要。建筑结构的形状和尺寸还可以通过模板的形状、尺寸和设计,根据需要进行配置。
下面的实例用于详细阐释本发明,并且不应该以任何方式认为构成限制。
粘结剂的配制品:
粘结剂1:找平灰浆、单组分:
粘结剂2:找平灰浆、二组分:
下面的组分A和B以重量比率为1:1使用。
组分A:
组分B:
粘结剂3:砌筑砂浆、单组分:
粘结剂4:砌筑砂浆、单组分:
粘结剂1至4的制备
根据DIN50014,在标准条件下通过搅拌,在常规混合机中均匀地混合除了水之外的粘结剂1、3和4的相应配方的成分。然后添加水,并且均匀混合。
在粘结剂2的情况下,首先彼此分开地以上述方式制备组分A和B,并且以在每种情况下指示的水的量进行混合。之后,组分A与组分B混合。
建筑元件的制造
根据DIN50014,在标准条件下,以5mm的层厚度将相应的粘结剂1至4均匀地施加到石膏板面板的基部区域上(尺寸:250cm×50cm×1.5cm)。然后,将具有锯齿形轮廓的金属丝格构网(wire lattice mesh)(金属丝格构的网孔尺寸:5cm×5cm;金属丝直径:1.5mm),均匀地压入到粘结剂层中,直到金属丝格构网接触石膏板面板为止。金属丝格构网从粘结剂层中突出约8cm。该构造大体上相应于图1中显示的实施例。在表1中指示的相应的凝结时间之后,根据DIN50014,在标准条件下,粘结剂固化,并且完成相应石膏板面板建筑元件。
以相同的方式,使用由膨胀型聚苯乙烯制成的绝缘板(EPS面板)(尺寸:250cm×50cm×10cm),用粘结剂1至4中的每一种,制造相应的EPS建筑元件。
模板和建筑结构的制造
两者都涂有上述粘结剂中同一种的石膏板面板建筑元件,还有EPS建筑元件,以其锯齿形轮廓重叠的方式通过具有金属丝格构网的侧面,放置在彼此上,两种不同建筑元件的金属丝格构网因此形成缝隙。作为插头元件在垂直方向上插入此类缝隙中的是线性金属棒(长度:250cm;直径:2mm)。总共地,与该第一金属棒平行,类似地安装三个另外的线性金属棒。以此方式,石膏板面板建筑元件结合到EPS建筑元件上,并且制造了模板元件。两个建筑元件之间的空腔约16cm。模板重量/单位面积为11.3kg/cm2。该构造大体上相当于图2中显示的实施例。
用于模板的填充材料是下面配方的混凝土:
为了制造混凝土,在强制式搅拌机中首先将所有波特兰矿渣水泥,然后将B16砂砾预先混合,然后,在混合机运转下,添加水,并且将混合物混合另外三分钟。五分种的停止时间之后,在混合机运转下添加增塑剂,其后将混合机混合一分钟。
以填充整个空腔的方式将得到的混凝土引入到上述模板中的空腔中。在20℃和50%相对湿度下储存(干燥储存)28天之后,混凝土固化,并且完成建筑结构。
性能测试
如下测试EPS建筑元件:
在表1说明的储存之后,根据欧洲标准ETAG 004测定EPS建筑元件的绝缘板上加强筋的抗拉粘结强度。
在表1说明的储存之后,根据欧洲标准ETAG 004测定从建筑元件中拔出(pull-out)加强筋。
在表1说明的储存之后,根据DIN EN 206-1在标准条件下,在储存28天之后使用粘结剂的棱柱(prism)(40mm×40mm×160mm),来测定压缩强度。
测试的结果总结在表1中。
表1:建筑元件的制造和测试:
实例 | 1 | 2 | 3 | 4 |
粘结剂 | 1 | 2 | 3 | 4 |
凝结时间[min] | 20-30 | 5-10 | 20-30 | 30-60 |
干燥储存后抗拉粘结强度[N/mm2] | 0.25 | 0.23 | 0.25 | 0.20 |
干燥储存后拔出[%] | 100 | 100 | 100 | 100 |
湿储存a)后抗拉粘结强度[N/mm2] | 0.15 | 0.12 | 0.12 | 0.11 |
湿储存a)后拔出[%] | 85 | 90 | 80 | 90 |
压缩强度 | 40-50 | 35-45 | 40-50 | 35-45 |
a)湿润储存:在干燥储存之后,将两个建筑元件储存在23℃的水中两天,然后在23℃和50%相对湿度下储存两个小时。
Claims (11)
1.一种通过用粘结剂将加强筋紧固到绝缘板上而得到的建筑元件,
所述粘结剂包含一种或多种无机物粘合剂和/或一种或多种聚合物粘合剂,和可选地一种或多种填料,可选地一种或多种佐剂以及可选地一种或多种添加剂,并且
所述加强筋部分地但并非全部地嵌入在所述粘结剂中。
2.根据权利要求1所述的建筑元件,其特征在于,一种或多种聚合物粘合剂选自包括以下的组:聚氨酯、聚酯、乙烯基酯、聚环氧化物、聚酰胺和基于烯属不饱和单体的聚合物。
3.根据权利要求1所述的建筑元件,其特征在于,选择的聚合物粘合剂是基于选自包括以下的组的一种或多种烯属不饱和单体的一种或多种聚合物:乙烯基酯、(甲基)丙烯酸酯、乙烯基芳烃、烯烃、1,3-二烯、和乙烯基卤化物,以及可选地可与它们共聚的另外的单体。
4.根据权利要求3所述的建筑元件,其特征在于,所述聚合物以水性分散体的形式,或以可再分散于水中的粉末形式存在。
5.根据权利要求1至4所述的建筑元件,其特征在于,所述绝缘板具有50至500cm长度,20至150cm宽度,以及1至50cm厚度。
6.根据权利要求1至5所述的建筑元件,其特征在于,所述加强筋基于有机材料,例如塑料,或者基于无机材料,例如金属或无机纤维。
7.根据权利要求1至6所述的建筑元件,其特征在于,所述粘结剂包含
0.1至95wt%的聚合物粘合剂,
1至95wt%的无机物粘合剂,
5至95wt%的填料,
可选地0.01至1wt%的增塑剂,
可选地0.01至1wt%的增稠剂,
可选地一种或多种另外的佐剂,以及可选地一种或多种添加剂;
以wt%表示的数字是基于所述粘结剂的干重,并且加起来合计100wt%。
8.根据权利要求1至7所述的建筑元件,其特征在于,在所述绝缘板上所述粘结剂(粘结剂层)的施加厚度为2至80mm。
9.根据权利要求1至8所述的建筑元件,其特征在于,所述加强筋从所述粘结剂层突出5至500mm。
10.根据权利要求1至9中所述的建筑元件用于生产模板的用途。
11.根据权利要求1至9中所述的建筑元件或者根据权利要求10所述的模板用于生产建筑结构,例如墙壁、地板、天花板或建筑结构的用途。
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Also Published As
Publication number | Publication date |
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WO2012069333A1 (de) | 2012-05-31 |
US20130295378A1 (en) | 2013-11-07 |
DE102010062061A1 (de) | 2012-05-31 |
BR112013012997A2 (pt) | 2016-09-13 |
EP2643531A1 (de) | 2013-10-02 |
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