DE102010062061A1 - Components in plate form - Google Patents

Abstract

The invention relates to components which can be obtained by fixing reinforcement with adhesive to insulating boards, the adhesive comprising one or more mineral binders and / or one or more polymeric binders, and optionally one or more fillers, optionally one or more additives and optionally one or more additives contains, and the reinforcement is partially, but not completely embedded in the adhesive.

Description

The invention relates to components and their use for the production of formwork and structures.

In the construction sector, the use of formwork for the construction of structures has long been established. Traditionally, shuttering walls made of wood or composite materials are used. The formwork is usually placed on the construction site and filled with building material, such as concrete. After setting the concrete, the formwork is removed and the bare, raw wall or floor or ceiling is erected. Disadvantageously, this must be purchased with the formwork, an additional tool and be provided during the construction of the site, which is not part of the building. In addition, the construction of the formwork and the previous pretreatment of the formwork with Dehäsiven, such as formwork oil, and degradation and subsequent cleaning of the formwork is associated with considerable effort.

Therefore, there is a need for more efficient, flexible and versatile approaches to fabricate structures, particularly using prefabricated components. For example, cages made of steel mesh have been proposed, which may have the shape and dimensions of a wall, and whose enclosed interior is filled with insulating materials, such as polystyrene or polyurethane foam. Such steel grid plates can be connected to each other via the steel mesh or hung on a frame. Surfaces and spaces can be plastered and filled with shotcrete or mortar. However, the static properties of such components are limited. Of particular disadvantage, however, is that the insulating properties of the steel grid plates despite the extensive use of insulation materials are unsatisfactory, since the steel of the steel grid plates connects the inside and the outside of the wall and acts as a cold bridge.

To similar unsatisfactory insulation properties lead components in which the insulation boards serving for the insulation of an outer or inner wall are used as shuttering walls, which are fixed by means of spacers made of metal. These spacers are passed through the insulation boards. Usually more than ten spacers per square meter are required. The prefabricated components are then filled, for example, with concrete, so that concrete walls are obtained, which are isolated on the inside and outside with insulation boards. The effort to demould the concrete walls is therefore eliminated. However, the spacers act as a cold bridge. In addition, the spacers can adversely affect the statics of the walls.

Against this background, the task was to provide measures by which the insulation boards commonly used insulation boards can be used as formwork, which formwork should remain in the building and the structures thus obtained should have improved thermal insulation. In addition, these measures should have an advantageous effect on the statics of the structures and can be flexibly adapted to any configuration of the structures in terms of shape, weight or usable materials. In this case, a flexible adaptation of the components should be made possible to the requirements of the respective application site, such as water resistance, water vapor permeability or mechanical properties. Furthermore, low weight components, ie. H. With low densities, be made accessible, so that the components can be easily transported by people without tools, such as cranes.

The invention relates to components obtainable by fixing reinforcement with adhesive on insulation boards,
wherein the adhesive contains one or more mineral binders and / or one or more polymeric binders, and optionally one or more fillers, optionally one or more additives and optionally one or more additives, and
the reinforcement is partially, but not completely embedded in the adhesive.

The insulation boards are generally based on organic or inorganic, natural or artificial insulation materials. Examples of artificial insulating materials are plastic materials, such as polystyrene, in particular expanded or extruded polystyrene, or polyurethane, in particular polyurethane foams, mineral materials, in particular mineral fiber, mineral wool or mineral foams, or bitumen.

Examples of natural, inorganic insulating materials are gypsum or cement based materials.

Examples of natural, organic insulating materials are wood, especially in the form of wood boards, chipboard, plywood boards, wood fiber boards, plywood, OSB (Oriented Strand Board), grasses or stalks.

Fibrous insulating materials, such as mineral wool, wood fibers, wood wool, grasses or stalks, are generally bound with mineral or organic binders and made into sheet form. The production of the insulation boards is known to the skilled person but.

Insulation boards have a low thermal conductivity and are therefore suitable for thermal insulation, for example of buildings. In addition, the insulation boards have a sound-insulating effect. The thermal conductivity of the insulating boards is preferably 0.001 to 60 W / mK, more preferably 0.002 to 5 W / mK and most preferably 0.004 to 3 W / mK (determined according to DIN 18159T.1 for plastic materials, after DIN 18165 for mineral materials, after DIN 52128 for bitumen, after DIN 18180 for gypsum-based systems, after DIN 18550 T3 or DIN 1045 for cement-based systems, after DIN 68705 for wood).

The dimensions of the insulation boards can be arbitrary. The insulation boards generally have a width of 20 to 150 cm and a length of 50 to 500 cm. The thickness of the insulating panels is preferably 1 to 50 cm, more preferably 3 to 30 cm and most preferably 5 to 20 cm. The density of the insulation boards is preferably 5 to 2500 kg / m ³ , more preferably 10 to 100 kg / m ³ , and most preferably 15 to 50 kg / m ³ . The insulating materials therefore preferably have a low density.

The insulation boards may be laminated on their top and / or bottom with a cover material, such as with cardboard, paper, aluminum foil, bitumen, disperse silicate paint or dimpled film. An example of this is plasterboard.

It can also be processed into a laminate two or more insulation boards. A laminate generally comprises two or more insulating panels, which are mounted one on top of the other and fixed together. The fixation of the individual insulation boards of a laminate is usually done by gluing, but can alternatively be achieved by screwing or other fixation methods. Preferably, a laminate comprises one or more gypsum board and one or more insulating boards based on insulating materials selected from the group consisting of expanded polystyrene, extruded polystyrene and mineral wool; or one or more polystyrene panels and one or more insulation panels based on insulation materials selected from the group consisting of wood wool and mineral wool.

The reinforcement is generally based on organic materials, such as plastics, or inorganic materials, such as metals, in particular steel, or inorganic fibers, in particular carbon fiber or glass fibers.

Metals are preferably in the form of wires, mesh mats or expanded meshes, which in turn form a three-dimensional, d. H. are not shaped purely planar profile. The metals preferably have a wavy or zigzag profile. The wires preferably have a diameter of 0.1 to 30 mm, more preferably 1 to 10 mm. Grid mats can be produced for example by linking wires or wire mesh.

Inorganic fibers are preferably in the form of nets or fabrics.

For example, plastics may be in the form of mesh mats or expanded metal meshes shaped as wavy or zigzag profiles, or in the form of nets or fabrics. Wires, lattice mats or expanded mesh therefore generally do not consist exclusively of substantially planar materials, such as linear wires or flat mesh mats or flat expanded meshes.

Suitable mineral binders are, for example, cement, in particular Portland cement, aluminate cement, in particular calcium sulfo-aluminate cement, trass cement, metallurgical cement, magnesia cement, phosphate cement or blast-furnace cement, as well as mixed cement, filler cements, fly ash, microsilica, granulated slag, hydrated lime, hydrated lime, calcium oxide (quicklime). and plaster. Portland cement, aluminate cement and slag cement, as well as mixed cements, filler cements, hydrated lime, hydrated lime or gypsum are preferred.

Also preferred are adhesives containing at least two mineral binders. In a particularly preferred embodiment, the adhesives contain aluminate cement and one or more further mineral binders. Preferably, 0.01 to 99 parts by weight, particularly preferably 0.05 to 10 Parts by weight and most preferably 0.1 to 5 parts by weight of aluminate cement, based on the parts by weight of the further mineral binder used. The use of aluminate cement leads to a particularly rapid drying of the adhesive and in combination with polymeric binders to a good adhesion of the adhesive on the insulation boards and the reinforcement, especially metals.

In a further preferred embodiment of the adhesive come as binders only mineral binders, d. H. no polymeric binders are used. In an equally preferred embodiment of the adhesive come as a binder exclusively polymeric binder, d. H. no mineral binders are used. More preferably, however, the adhesives contain one or more mineral binders and one or more polymeric binders.

Suitable polymeric binders are, for example, polyurethanes, polyesters, vinyl esters, polyepoxides or polyamides or preferably polymers based on ethylenically unsaturated monomers.

The polymers based on ethylenically unsaturated monomers are based, for example, on one or more ethylenically unsaturated monomers selected from the group comprising vinyl esters, (meth) acrylic esters, vinylaromatics, olefins, 1,3-dienes and vinyl halides and optionally other monomers copolymerizable therewith.

Suitable vinyl esters are, for example, those of carboxylic acids having 1 to 15 C atoms. Preference is given to vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, vinyl laurate, 1-methylvinyl acetate, vinyl pivalate and vinyl esters of α-branched monocarboxylic acids having 9 to 11 C atoms, for example VeoVa9 ^R or VeoVa10 ^R (trade name of the company Resolution). Particularly preferred is vinyl acetate.

Suitable monomers from the group of acrylic esters or methacrylic esters are, for example, esters of unbranched or branched alcohols having 1 to 15 C atoms. Preferred methacrylic esters or acrylates are methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate. Particularly preferred are methyl acrylate, methyl methacrylate, n-butyl acrylate, t-butyl acrylate and 2-ethylhexyl acrylate.

Preferred vinyl aromatic compounds are styrene, methylstyrene and vinyltoluene. Preferred vinyl halide is vinyl chloride. The preferred olefins are ethylene, propylene and the preferred dienes are 1,3-butadiene and isoprene.

If appropriate, from 0 to 10% by weight, based on the total weight of the monomer mixture, of auxiliary monomers, can be copolymerized. Preferably, 0.1 to 5 wt .-% auxiliary monomers are used. Examples of auxiliary monomers are ethylenically unsaturated mono- and dicarboxylic acids, preferably acrylic acid, methacrylic acid, fumaric acid and maleic acid; ethylenically unsaturated carboxylic acid amides and nitriles, preferably acrylamide and acrylonitrile; Mono- and diesters of fumaric acid and maleic acid, such as diethyl and diisopropyl esters and maleic anhydride; ethylenically unsaturated sulfonic acids or salts thereof, preferably vinylsulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid. Further examples are precrosslinking comonomers, such as multiply ethylenically unsaturated comonomers, for example diallyl phthalate, divinyl adipate, diallyl maleate, allyl methacrylate or triallyl cyanurate, or post-crosslinking comonomers, for example acrylamidoglycolic acid (AGA), methyl acrylamidoglycolic acid methyl ester (MAGME), N-methylolacrylamide (NMA), N-methylol methacrylamide, N- Methylolallyl carbamate, alkyl ethers such as the isobutoxy ether or esters of N-methylolacrylamide, N-methylolmethacrylamide and N-methylolallylcarbamate. Also suitable are epoxide-functional comonomers such as glycidyl methacrylate and glycidyl acrylate. Further examples are silicon-functional comonomers, such as acryloxypropyltri (alkoxy) - and Methacryloxypropylri (alkoxy) silanes, Vinyltrialkoxysilane and Vinylmethyldialkoxysilane, which may be contained as alkoxy, for example, ethoxy and Ethoxypropylenglykolether residues. Mention may also be made of monomers having hydroxyl or CO groups, for example methacrylic acid and acrylic acid hydroxyalkyl esters such as hydroxyethyl, hydroxypropyl or hydroxybutyl acrylate or methacrylate, and compounds such as diacetoneacrylamide and acetylacetoxyethyl acrylate or methacrylate.

Preference is given to one or more polymers selected from the group comprising vinyl ester homopolymers, vinyl ester copolymers containing one or more monomer units from the group comprising vinyl esters, olefins, vinyl aromatics, vinyl halides, acrylic esters, methacrylic acid esters, fumaric and / or maleic mono- or diesters; (Meth) acrylic acid ester homopolymers, (meth) acrylic ester mixed polyisocyanates containing one or more monomer units from the group comprising Methacrylic acid esters, acrylic esters, olefins, vinylaromatics, vinyl halides, fumaric and / or maleic acid mono- or diesters; Homopolymers or copolymers of dienes such as butadiene or isoprene, and of olefins such as ethene or propene, wherein the dienes may be copolymerized, for example with styrene, (meth) acrylic acid esters or the esters of fumaric or maleic acid; Homopolymers or copolymers of vinylaromatics, such as styrene, methylstyrene, vinyltoluene; Homo- or copolymers of vinyl halide compounds such as vinyl chloride, wherein the polymers may also contain auxiliary monomers.

Particularly preferred are copolymers of one or more vinyl esters with 1 to 50 wt .-% of ethylene; Copolymers of vinyl acetate with 1 to 50 wt .-% of ethylene and 1 to 50 wt .-% of one or more other comonomers from the group of vinyl esters having 1 to 12 carbon atoms in the carboxylic acid radical such as vinyl propionate, vinyl laurate, vinyl esters of alpha-branched carboxylic acids with 9 to 13 C atoms, such as VeoVa9, VeoVa10, VeoVa11; Copolymers of one or more vinyl esters, 1 to 50 wt .-% of ethylene and preferably 1 to 60 wt .-% of (meth) acrylic acid esters of unbranched or branched alcohols having 1 to 15 carbon atoms, in particular n-butyl acrylate or 2-ethylhexyl acrylate; and copolymers having 30 to 75 wt .-% vinyl acetate, 1 to 30 wt .-% vinyl laurate or vinyl ester of an alpha-branched carboxylic acid having 9 to 11 carbon atoms, and 1 to 30 wt .-% of (meth) acrylic acid esters of unbranched or branched alcohols having 1 to 15 carbon atoms, in particular n-butyl acrylate or 2-ethylhexyl acrylate, which still contain 1 to 40 wt .-% of ethylene; Copolymers with one or more vinyl esters, 1 to 50% by weight of ethylene and 1 to 60% by weight of vinyl chloride; wherein the polymers can still contain the said auxiliary monomers in the stated amounts, and the data in wt .-% add up to each 100 wt .-%.

Also particularly preferred are (meth) acrylic acid ester polymers, such as copolymers of n-butyl acrylate or 2-ethylhexyl acrylate or copolymers of methyl methacrylate with n-butyl acrylate and / or 2-ethylhexyl acrylate; Styrene-acrylic acid ester copolymers with one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate; Vinyl acetate-acrylic acid ester copolymers with one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate and optionally ethylene; Styrene-1,3-butadiene copolymers; wherein the polymers can still contain auxiliary monomers in the stated amounts, and the information in wt .-% add up to each 100 wt .-%.

Examples of particularly preferred comonomers for vinyl chloride copolymers are α-olefins, such as ethylene or propylene, and / or vinyl esters, such as vinyl acetate, and / or acrylic esters or methacrylic esters of alcohols having 1 to 15 C atoms, such as methyl acrylate, methyl methacrylate, ethyl acrylate , Ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, t-butyl acrylate, n-butyl methacrylate, t-butyl methacrylate, 2-ethylhexyl acrylate and / or fumaric and / or maleic acid mono- or diesters such as the dimethyl, methyl-t-butyl , Di-n-butyl, di-t-butyl and diethyl esters of maleic acid and fumaric acid, respectively.

Most preferred are copolymers with vinyl acetate and 5 to 50 wt .-% of ethylene; or copolymers with vinyl acetate, 1 to 50 wt .-% of ethylene and 1 to 50 wt .-% of a vinyl ester of α-branched monocarboxylic acids having 9 to 11 carbon atoms; or copolymers with 30 to 75 wt .-% vinyl acetate, 1 to 30 wt .-% vinyl laurate or vinyl ester of an alpha-branched carboxylic acid having 9 to 11 carbon atoms, and 1 to 30 wt .-% of (meth) acrylic acid esters of unbranched or branched alcohols having 1 to 15 carbon atoms, which still contain 1 to 40 wt .-% of ethylene; or copolymers with vinyl acetate, 5 to 50 wt .-% of ethylene and 1 to 60 wt .-% vinyl chloride.

Most preferred copolymers are also vinyl chloride-ethylene copolymers containing 60 to 98 wt .-% vinyl chloride units and 1 to 40 wt .-% ethylene units, wherein the data in wt .-% based on the total weight of the copolymer and each refer to 100th Add% by weight. Such vinyl chloride-ethylene copolymers are made EP 0 149 098 A2 known.

The monomer selection or the selection of the weight proportions of the comonomers is carried out so that a glass transition temperature Tg of -50 ° C to + 30 ° C, preferably -40 ° C to + 10 ° C, particularly preferably -30 ° C to 0 ° C. results. The glass transition temperature Tg of the polymers can be determined in a known manner by means of differential scanning calorimetry (DSC). The Tg can also be approximated by the Fox equation. To Fox TG, Bull. Physics Soc. 1, 3, Page 123 (1956) where: 1 / Tg = x1 / Tg1 + x2 / Tg2 + ... + xn / Tgn, where xn is the mass fraction (wt% / 100) of the monomer n, and Tgn is the glass transition temperature in Kelvin of the homopolymer of the monomer n is. Tg values for homopolymers are in Polymer Handbook 2nd Edition, J. Wiley & Sons, New York (1975) listed.

The preparation of the polymers based on ethylenically unsaturated monomers can be carried out by bulk or solution polymerization or, preferably, emulsion or suspension polymerization processes. The emulsion or suspension polymerization is generally carried out in an aqueous medium - such as in US Pat DE-A 10 2008 043 988 described. The polymers are obtained in the form of aqueous dispersions. In the polymerization, the common protective colloids and / or emulsifiers can be used, as in DE-A 10 2008 043 988 described. The protective colloids may be anionic or preferably cationic or more preferably nonionic.

Combinations of cationic and nonionic protective colloids are also preferred. Preferred nonionic protective colloids are polyvinyl alcohols. Preferred cationic protective colloids are polymers which carry one or more cationic charges, such as in EW Flick, Water Soluble Resins - An Industrial Guide, Noyes Publications, Park Ridge, NJ, 1991 , described. Partially hydrolyzed or fully saponified polyvinyl alcohols having a degree of hydrolysis of 80 to 100 mol% and having a degree of hydrolysis of 80 to 94 mol% and a Höppler viscosity, in 4% aqueous solution of 1 to 30 mPas (method according to US Pat Höppler at 20 ° C, DIN 53015 ). The said protective colloids are obtainable by methods known to the person skilled in the art and are generally added in an amount of in total from 1 to 20% by weight, based on the total weight of the monomers, in the polymerization.

The polymers in the form of aqueous dispersions can, as in the DE-A 10 2008 043 988 described be converted into corresponding water-redispersible powder. As a rule, a drying aid in a total amount of from 3 to 30% by weight, preferably from 5 to 20% by weight, based on the polymeric constituents of the dispersion, is used. As a drying aid, the aforementioned polyvinyl alcohols are preferred.

Examples of suitable fillers are quartz sand, quartz powder, limestone powder, calcium carbonate, dolomite, clay, chalk, hydrated lime, talc or mica, rubber granules or hard fillers such as aluminum silicates, corundum, basalt, carbides such as silicon carbide or titanium carbide, or pozzolanically reactive fillers such as fly ash , Metakaolin, microsilica, diatomaceous earth. Preferred fillers are silica sand, quartz flour, limestone flour, calcium carbonate, calcium magnesium carbonate (dolomite), chalk or hydrated lime.

Preference is also the use of lightweight fillers. Light fillers are fillers of low bulk density, usually less than 500 g / l. Typical lightweight fillers are, on a synthetic or natural basis, materials such as hollow glass microspheres, polymers such as polystyrene beads, aluminosilicates, silica, aluminum-silicon oxide, calcium silicate hydrate, silica, aluminum silicate, magnesium silicate, aluminum-slicate hydrate, calcium aluminum alloy. Silicate, calcium silicate hydrate, aluminum-iron-magnesium silicate, calcium metasilicate and / or volcanic slag. The shape of the lightweight fillers is not limited and may in particular have a spherical, platelet, rod-shaped and / or lamellar structure. Preferred light fillers are Perlite, Cellite, Cabosil, Circosil, Eurocell, Fillite, Promaxon, Vermex and / or Wollastonite and polystyrene.

It is also possible to use any desired mixtures of the stated fillers. Preferred mixtures comprise at least two different fillers. Preferred blends contain one or more carbonaceous fillers and one or more further fillers. Carbonatic fillers are preferably selected from the group comprising calcium carbonate, chalk, dolomite and limestone. Preferred mixtures preferably contain from 5 to 60% by weight, more preferably from 10 to 50% by weight, and most preferably from 20 to 50% by weight of carbonaceous fillers, based on the total weight of the total fillers used. By using carbonaceous fillers, the mechanical strength of the adhesive can be increased.

The fillers have diameters of preferably from 0.1 μm to 4 mm, more preferably from 1 μm to 2 mm, and most preferably from 1 μm to 1 mm. In a particularly preferred embodiment, the fillers do not comprise gravel. Gravel generally has a diameter of> 2 mm.

Preferred formulations for the adhesives included
preferably 0.1 to 95% by weight, more preferably 0.1 to 30% by weight, and most preferably 0.5 to 10% by weight of polymeric binder;
preferably 1 to 95% by weight, more preferably 5 to 80% by weight, and most preferably 20 to 50% by weight of mineral binders;
preferably 5 to 95% by weight, more preferably 30 to 85% by weight, and most preferably 49 to 75% by weight of fillers; wherein the data in wt .-% on the dry weight of the adhesive refer and add up to 100 wt .-% total.

In a preferred embodiment, the adhesives contain as an additive one or more tiling agents selected from the group consisting of casein, ligninsulfonates, melamine and polycarboxylates. Tiling agents are also known by the terms leveling agent or condenser. Tiling agents are preferably contained in the adhesives to 0.01 to 1 wt .-%, based on the dry weight of the adhesive. Such adhesives are also referred to as leveling mortar. Gradient mortar lead to components in which the reinforcements are particularly firmly connected to the insulation boards.

In a further preferred embodiment, the adhesives contain as an additive one or more thickeners from the group comprising polysaccharides such as cellulose ethers and modified cellulose ethers, starch ethers, guar gum, xanthan gum, polycarboxylic acids such as polyacrylic acid and their partial esters, and also polyvinyl alcohols which may be acetalated or hydrophobically modified casein and associative thickeners. Thickening agents are preferably contained in the adhesives at 0.01 to 1% by weight, based on the dry weight of the adhesives. Such adhesives are also referred to as adhesive mortar. The adhesive mortars preferably contain ≤ 0.005% by weight of the solvent, based on the dry weight of the adhesive mortar.

A common additive for the adhesives are also one or more setting accelerators, such as alkali or alkaline earth salts or aluminum salts of inorganic or organic acids. Preferred setting accelerators are aluminum salts, aluminates, alkali metal silicates, such as, for example, water glass, alkali metal carbonates or potassium hydroxide. Particularly preferred setting accelerators are aluminum sulfate, alkali aluminates such as potassium aluminate, aluminum hydroxides, potassium carbonate or sulfoaluminates such as calcium sulfoaluminate. Setting accelerators are contained in the adhesives preferably at 0 to 2 wt .-%, more preferably at 0.1 to 1 wt .-% and most preferably at 0.1 to 0.5 wt .-%, based on the dry weight of Glue.

Typical additives for the adhesives are water repellents, such as fatty acids or their derivatives, such as esters, or silicones. Typical additives are also retarders, such as hydroxycarboxylic acids, or dicarboxylic acids or their salts, saccharides, oxalic acid, succinic acid, tartaric acid, gluconic acid, citric acid, sucrose, glucose, fructose, sorbitol, pentaerythritol. Common additives are also crosslinkers such as metal or semimetal oxides, in particular boric acid or polyborates, or dialdehydes, such as glutaric dialdehyde; Further additives are fibers such as keflar, viscose fibers, polyamide fibers, polyester fibers, polyacrylonitrile fibers, dralon fibers, polyethylene fibers, polypropylene fibers, polyvinyl alcohol fibers, aramid fibers or carbon fibers. In addition, preservatives, film-forming aids, dispersants, foam stabilizers, defoamers and flame retardants (eg aluminum hydroxide) may be mentioned.

In general, the proportion of additives in the adhesives is a total of 0 to 20 wt .-%, preferably 0.1 to 15 wt .-% and particularly preferably 0.1 to 10 wt .-%, each based on the dry weight of the adhesive.

Generally, water is added to the adhesives prior to application. The aqueous adhesives obtainable in this way preferably contain 10 to 90% by weight and more preferably 15 to 50% by weight of water, based on the dry weight of the adhesive.

The adhesives are preferably premixed in the form of dry blends. Dry mixtures preferably contain all constituents of the respective recipe, except for water. The adhesives are therefore preferably one-component systems.

The adhesives can also be used as two-component systems. In two component systems, the first component contains one or more aluminate cements, one or more polymeric binders, one or more fillers, optionally one or more additives, and optionally one or more additives, and water. The second component corresponds to the first component, with the difference that instead of aluminate cement one or more other mineral binders are contained. The proportions by weight of the individual constituents of the first component and of the second component fulfill the specifications of the above-mentioned formulation of the adhesive. The first component and the second component are used in a ratio of 1: 3 to 3: 1, based in each case on their dry masses. The first and second components can be mixed in common mixing equipment. After mixing the Both components solidify the adhesive after a few seconds to minutes. Solidification of the adhesives can also be controlled by the use of setting accelerators. Two-component systems are particularly advantageous in the industrial production of the components, if rapid setting or drying times of the adhesive and a continuous but interruptible process control is desired.

Two-component systems are in particular when using leveling mortars, d. H. Tween-containing adhesive, preferably.

The preparation of the adhesive is not bound to any particular procedure or mixing device. Adhesives are obtainable by mixing and homogenizing the individual constituents of the formulation in conventional powder mixing devices, for example by means of mortar, concrete mixers or plastering machines or stirrers.

The polymeric binders can be used, for example, in the form of prefabricated dispersion adhesives, as are available on the market. The polymers based on ethylenically unsaturated monomers are preferably used in the form of aqueous dispersions or particularly preferably in the form of water-redispersible powders. The dispersions have a solids content of preferably 1 to 80%, more preferably 5 to 70% and most preferably 10 to 60%.

To fix reinforcement on an insulation board, first the adhesive and then the reinforcement can be applied to the insulation board. Alternatively, first the reinforcement can be laid out on the insulating board and then the adhesive can be applied. In this way, the components are preserved.

Here, the entire surface of one side of an insulating board can be provided with an adhesive layer. Preferably, however, the adhesive is applied in the form of adhesive sheets or adhesive dots on one side of the insulation boards. The adhesives can also be introduced into recesses of the insulation boards. Recesses can be made by removing material from, for example, milled or cut out of the insulation panels, or by using a laminate in which the topmost layer does not completely cover the underlying layer or layers so that the laminate contains a recess , When applying adhesive dots or adhesive sheets on the insulation boards components are obtained with lighter weight, which facilitates the handling of the components.

The application thickness of the adhesive (adhesive layer) is preferably 2 to 80 mm and more preferably 3 to 50 mm. The adhesive dots are preferably approximately circular and have diameters of preferably 20 to 200 mm. The adhesive sheets may have a length depending on the insulation boards. The adhesive sheets are preferably 20 to 200 mm wide. These application thicknesses or the dimensions of the adhesive dots or adhesive sheets have an advantageous effect on the mechanical stability and the load-bearing capacity of the components or formwork with at the same time low weight of the components or formworks.

The reinforcement preferably projects from 5 to 500 mm, more preferably 50 to 300 mm and most preferably 100 to 200 mm out of the adhesive or the adhesive layer. The reinforcement is thus partially, but not completely embedded in the adhesive. When using the components for the production of formwork, the protruding from the adhesive reinforcement can be used to attach various components.

The application of the adhesive to the insulation boards is not bound to any special procedure and can be done, for example, manually or mechanically, for example by using injection molding machines.

After curing of the adhesive or after solidification of the adhesive by any drying the reinforcement is firmly connected to the insulation boards.

Preferred embodiments of the components are in 1 shown. The two components shown therein each consist of one element ( 1 ) 2 ) and ( 3 ). In 1 is on the two insulation boards ( 1 ), which have a different thickness and are based on different materials, each having an adhesive layer ( 2 ), in which as reinforcement ( 3 ) each a metal wire, which has a zigzag profile, is embedded. The reinforcements ( 3 ) are thus partially, but not completely, in the adhesive layers ( 2 ) and thus protrude from the adhesive layers ( 2 ) out. The 1 is a cross section through the reinforcements ( 3 ) of the components.

In a special embodiment of the components, one or more coatings can be applied to the components, such as, for example, one or more plasters or paints. In general, the coating is applied to the side of the insulating panel opposite the armored side of the components. First, the reinforcement can be applied to the insulation boards and then one or more coatings. Alternatively, one or more coatings can first be applied to the insulation boards and then the reinforcement.

The design of the coatings is basically arbitrary and depends on the requirements of the components or the structures to be produced and can, for example, be adapted accordingly to the special requirements for interior or exterior walls. The requirements are, for example, compressive strengths, capillary water absorption, impact resistance or water vapor permeability. To prepare the coatings, the adhesives described above can also be used as coating agents. In the case of industrial manufacturing of the components, d. H. in mass production of the components, the coating compositions are preferably applied in the form of the two-component systems described above.

It can also installations such as gas, water or sewer pipes, electrical cables or hollow tubes are applied to the components.

Another object of the invention is the use of the components according to the invention for the production of formwork. Shutterings are obtainable by placing components facing one another such that the sides of the components provided with the reinforcement face each other, and the components are linked together by the part of the reinforcement that is not completely embedded in the adhesive. In this way creates a cavity between the components.

In a preferred embodiment, the components are arranged relative to one another in such a way that the reinforcements (profiles) formed as wavy lines or zigzag patterns approximate one another or preferably overlap one another. In this way, the components can be linked via the reinforcements in a particularly advantageous manner. When the profiles overlap, eyelets are formed, into which a plug element, for example a metal rod, preferably a substantially linear metal rod, can be inserted. The metal rod has a diameter of preferably 1 to 50 mm, and more preferably 1.5 to 20 mm. The length of the metal rod can vary, but usually depends on the dimensions of the insulation boards. In this way, the components are connected to one another in a technically particularly simple and efficient manner. A preferred variant of this embodiment of the formwork is in 2 displayed. The two components described above 1 are each other in 2 so far approximated that the reinforcements ( 3 ) overlap the two components and form eyelets in this way, in each of which a metal rod ( 4 ) is inserted as a plug-in element, so that the two components are linked together. The 2 is a cross section through the reinforcements ( 3 ) of the formwork.

Alternatively, the reinforcements of different components can be hooked together in some other way. In a further variant, the linking of components can also take place via tongue and groove systems.

In another alternative approach, the formworks are obtainable by joining at least two insulating panels by means of at least one reinforcement, by fixing at least one reinforcement with adhesive on different insulating panels so that the reinforcement is partly, but not completely, embedded in the adhesive. In this way formworks are obtained starting from insulation boards in one step. This approach is particularly preferred when using plastic materials or insulation materials in fiber form as reinforcements. Such insulating materials lead to collapsible or foldable formwork, which can then be unfolded again at a later date, for example, for their application on the construction site. Folded components can be stored and transported more easily and efficiently.

The formwork can be delivered prefabricated to the construction site or made on site at the construction site.

For the production of buildings located in the formwork between the structural elements cavity is filled. For this purpose, any filler material, such as concrete, lightweight concrete or mortar, optionally in combination with lightweight fillers, can be used. As filler can also be one or more Light fillers are used. For this purpose, for example, the above-mentioned lightweight fillers are suitable. Lightweight fillers preferred as filling material are expanded clay, expanded glass, perlite, clay, loam, injection fillers, such as cellulose fibers or shredded paper, or polymer-bound clay or loam. The lightweight fillers can be bound or unbound. Lightweight fillers are used in particular for interior walls of buildings.

The bulk densities of the filler materials are usually 10 to 2600 kg / m ³ , preferably 500 to 2600 kg / m ³ , more preferably 1500 to 2300 kg / m ³ and most preferably from 1800 to 2200 kg / m ³ . The bulk densities of the lightweight fillers are usually 10 to 2500 kg / m ³ and more preferably 100 to 1800 kg / m ³ . Lightweight materials lead to structures with particularly low weight and particularly high thermal insulation.

The components or structures may be provided with a low basis weight, such as preferably from 5 to 100 kg / m ² , more preferably from 5 to 50 kg / m ² and most preferably from 10 to 25 kg / m ² .

The entire cavity of the formwork can be filled with filling material in one step. Alternatively, the cavity can also be filled with filler in several steps. In the alternative approach, the formwork are exposed to a lower hydrostatic load when using, for example, concrete, lightweight concrete or mortar as filler, if the addition of further filler material takes place only when the previously added filler has dried or set.

The introduced filling material also improves the stability and statics of the formwork or structures. To further improve the stability of the components or the formwork on the ground, such as a screed can be fixed. For this purpose, common foam adhesive or mortar, in particular leveling mortar are suitable. As a result, unevenness of the ground can be compensated. For lateral fixation of the formwork or to prevent slippage of the formwork, the formwork can be made prepared in the ground recesses or supported by means of laterally mounted braces or strips.

Examples of buildings are walls, floors, ceilings or entire building constructions. Larger structures can be obtained by placing several formwork next to each other and filling them with filling material.

Surprisingly, the components or formwork are very stable to mechanical loads, so that the shuttering is not damaged by the introduction of the filling material for the production of the structures. The stability of the components can be increased by the combination of mineral binders and polymeric binders, in particular polymers based on ethylenically unsaturated monomers.

Due to the low weight and ease of handling of the components according to the invention, the construction of buildings by a single person, even without the use of tools, such as cranes done. Furthermore, the components according to the invention are also accessible by industrial production processes in a particularly time-consuming and cost-efficient manner. The structures of the invention are characterized by excellent insulation properties. The insulation panels used to make the formwork remain in the structures. The statics of buildings can be adapted by appropriate installation of reinforcements to the respective structural requirements. The shape and dimensions of the structures can be configured on the shape, size and shape of the formwork in any way.

The following examples are given to illustrate the invention in detail and are in no way to be considered as limiting.

Recipes of glue

Adhesive 1: leveling mortar, one-component: 180.00 parts by weight Portland Cement CEM I 42.5 R 120.00 parts by weight High Alumina Cement Fondu Lafarge 400.00 parts by weight Silica sand H33 (0.063-0.5 mm) 201.30 parts by weight Omyacarb 20 BG 70.00 parts by weight Bayer anhydrite 1.00 parts by weight Agitan P 800 (defoamer) 25.00 parts by weight Polyvinyl alcohol-stabilized, water-redispersible terpolymer of vinyl acetate, ethylene and an ethylenically unsaturated acrylate 0.50 part by weight Tylose H 300 P2 (cellulose ether) 0.50 part by weight Polycarboxylate ethers (Tile) 1.20 parts by weight Tartaric acid 1.00 parts by weight Lithium carbonates (Li ₂ CO ₃ ) 250.00 parts by weight Water.

Adhesive 2: leveling mortar, two-component:

The following components A and B were used in a weight ratio of 1: 1. Component A: 250.00 parts by weight Portland Cement CEM I 42.5 R 450.00 parts by weight Silica sand H33 (0.063-0.5 mm) 272.30 parts by weight Omyacarb 20 BG 1.00 parts by weight Agitan P 800 (defoamer) 25.00 parts by weight Polyvinyl alcohol-stabilized, water-redispersible terpolymer of vinyl acetate, ethylene and an ethylenically unsaturated acrylate 0.50 part by weight Tylose H 300 P2 (cellulose ether) 0.50 part by weight Polycarboxylate ethers (Tile) 1.20 parts by weight Tartaric acid 220.00 parts by weight Water. Component B: 250.00 parts by weight High Alumina Cement Fondu Lafarge 400.00 parts by weight Silica sand H33 (0.063-0.5 mm) 321.30 parts by weight Omyacarb 20 BG 1.00 parts by weight Agitan P 800 (defoamer) 25.00 parts by weight Polyvinyl alcohol-stabilized, water-redispersible terpolymer of vinyl acetate, ethylene and an ethylenically unsaturated acrylate 0.50 part by weight Tylose H 300 P2 (cellulose ether) 0.50 part by weight Polycarboxylate ethers (Tile) 1.20 parts by weight Tartaric acid 1.00 parts by weight Lithium carbonates (Li ₂ CO ₃ ) 220.00 parts by weight Water. Adhesive 3: adhesive mortar, one-component: 180.00 parts by weight Portland Cement CEM I 42.5 R 120.00 parts by weight High Alumina Cement Fondu Lafarge 400.00 parts by weight Silica sand H33 (0.063-0.5 mm) 201.30 parts by weight Omyacarb 20 BG 70.00 parts by weight Bayer anhydrite 1.00 parts by weight Agitan P 800 (defoamer) 25.00 parts by weight Polyvinyl alcohol-stabilized, water-redispersible copolymer of vinyl acetate and ethylene 1.20 parts by weight Tartaric acid (retarder) 1.00 parts by weight Lithium carbonates (Li ₂ CO ₃ ) 0.25 part by weight Methylcellulose Tylose 10,000 250.00 parts by weight Water. Adhesive 4: adhesive mortar, one-component: 300.00 parts by weight Portland Cement CEM I 42.5 R 464.00 Wt Silica sand H33 (0.063-0.5 mm) 200.00 parts by weight Omyacarb 20 BG 1.00 parts by weight Agitan P 800 (defoamer) 25.00 parts by weight Polyvinyl alcohol-stabilized, water-redispersible copolymer of vinyl acetate and ethylene 10.00 parts by weight Calcium formate (accelerator) 0.25 part by weight Methylcellulose Tylose 10,000 240.00 parts by weight water

Production of adhesives 1 to 4

The constituents of the respective formulation of adhesives 1, 3 or 4, except for water, were reduced in a conventional mixer by stirring under normal conditions DIN 50014 homogeneously mixed. Subsequently, the water was added and mixed homogeneously. In the case of adhesive 2, the components A and B were first prepared separately from each other in the manner described above and mixed with the specified amount of water. Subsequently, component A was mixed with component B.

Production of the components

The respective adhesive 1 to 4 was applied under normal conditions according to DIN 50014 in a layer thickness of 5 mm evenly on a base area of each gypsum plaster board (dimensions: 250 cm × 50 cm × 1.5 cm). Then, a wire mesh (mesh size of the wire mesh: 5 cm × 5 cm, diameter of the wire: 1.5 mm) having a zigzag profile was uniformly pressed into the adhesive layer until the wire mesh mesh abutted against the plasterboard. The wire mesh protruded about 8 cm from the adhesive layer. This structure is essentially the same as in 1 illustrated embodiment. After the respective setting time given in Table 1 under normal conditions DIN 50014 the adhesive had cured and completed the respective plasterboard component. In the same way, with the use of expanded polystyrene (EPS) insulation boards (dimensions: 250 cm × 50 cm × 10 cm), a corresponding EPS element was produced with each of the adhesives 1 through 4.

Production of formwork and structures

A plasterboard component and an EPS component, both coated with the same one of the aforementioned adhesives, became one another with the side provided with the wire mesh net contrasted that their zigzag profiles overlapped, so that the wire mesh of the two different components formed eyelets. In such eyelets, a linear metal rod (length: 250 cm, diameter: 2 mm) was inserted in the vertical direction as a plug-in element. Overall, three more linear metal rods were installed in an analogous manner parallel to this first metal rod. In this way, the plasterboard component was connected to the EPS component and made a formwork. The cavity between the two components was about 16 cm. The basis weight of the formwork was 11.3 kg / m ² . This structure is essentially the same as in 2 illustrated embodiment.

The filling material used for the formwork was a concrete of the following formulation: 370 kg / m ³ Portland hut cement CEM II / AS 42,5R, 1727 kg / m ³ Gravel 316 (grading curve 0 to 16 mm), 185 kg / m ³ Water, 0.75% by weight Melamine sulfonate (flow agent); In% by weight refers to cement.

To produce the concrete, first the Portland slag cement and the gravel B16 were premixed in the compulsory mixer, and then water was added while the mixer was running and the mixture was mixed for a further 3 min. After a rest period of 5 minutes, the flow agent was added while the mixer was running and the mixture was mixed in for 1 minute.

The concrete thus obtained was filled in the cavity of the above formwork, so that the entire cavity was filled. After 28 days storage at 20 ° C and 50% relative humidity (dry storage), the concrete had hardened and completed the building.

Application testing

The EPS components were tested as follows:
The tensile strength of the reinforcement on the insulation boards of the EPS components was determined according to the European standard ETAG 004 determined following the storage specified in Table 1. The eruption of the reinforcement from the building elements was after the European standard ETAG 004 determined following the storage specified in Table 1.

The compressive strength was checked by means of prisms (40 mm × 40 mm × 160 mm) of the adhesive after 28 days of storage under standard conditions DIN EN 206-1 determined following the storage specified in Table 1.

The results of the testing are summarized in Table 1. Table 1: Production and testing of the components: example 1 2 3 4 Glue 1 2 3 4 Setting time [min] 20-30 5-10 20-30 30-60 Adhesive tensile strength after dry storage [N / mm ² ] 0.25 0.23 0.25 0.20 Outbreak after dry storage [%] 100 100 100 100 Adhesive tensile strength after wet storage ^a) [N / mm ² ] 0.15 0.12 0.12 0.11 Extraction after wet storage ^a) [%] 85 90 80 90 Compressive strength 40-50 35-45 40-50 35-45 a) Wet storage: the component was stored for two days at 23 ° C in water following the dry storage and then stored for 2 hours at 23 ° C and 50% relative humidity.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0149098 A2 [0033]
• DE 102008043988 A [0035, 0035, 0037]

Cited non-patent literature

• DIN 18159T.1 [0011]
• DIN 18165 [0011]
• DIN 52128 [0011]
• DIN 18180 [0011]
• DIN 18550 T3 [0011]
• DIN 1045 [0011]
• DIN 68705 [0011]
• Fox TG, Bull. Physics Soc. 1, 3, Page 123 (1956) [0034]
• Polymer Handbook 2nd Edition, J. Wiley & Sons, New York (1975) [0034]
• EW Flick, Water Soluble Resins - Industrial Guide, Noyes Publications, Park Ridge, NJ, 1991 [0036]
• DIN 53015 [0036]
• DIN 50014 [0080]
• DIN 50014 [0081]
• European standard ETAG 004 [0086]
• European standard ETAG 004 [0086]
• DIN EN 206-1 [0087]

Claims (11)

Components obtainable by fixing reinforcement with adhesive on insulation boards, wherein the adhesive contains one or more mineral binders and / or one or more polymeric binders, and optionally one or more fillers, optionally one or more additives and optionally one or more additives, and the reinforcement is partially, but not completely embedded in the adhesive. Components according to claim 1, characterized in that one or more polymeric binders are selected from the group comprising polyurethanes, polyesters, vinyl esters, polyepoxides, polyamides and polymers based on ethylenically unsaturated monomers. Components according to claim 1, characterized in that as polymeric binder one or more polymers based on one or more ethylenically unsaturated monomers selected from the group comprising vinyl esters, (meth) acrylic acid esters, vinyl aromatics, olefins, 1,3-dienes and vinyl halides and optionally further monomers copolymerizable therewith can be selected. Components according to claim 3, characterized in that the polymers are present in the form of aqueous dispersions or in the form of water-redispersible powders 6. Components according to claim 1 to 4, characterized in that the insulating panels have a length of 50 to 500 cm, a width of 20 to 150 cm and a thickness of 1 to 50 cm. Components according to claim 1 to 5, characterized in that the reinforcement based on organic materials, such as plastics, or inorganic materials, such as metals or inorganic fibers. Components according to claim 1 to 6, characterized in that the adhesive 0.1 to 95% by weight of polymeric binders, From 1 to 95% by weight of mineral binders, From 5 to 95% by weight of fillers, optionally 0.01 to 1% by weight of flow agent, optionally 0.01 to 1% by weight of thickener, optionally one or more further additives and optionally contain one or more additives; wherein the data in wt .-% on the dry weight of the adhesive refer and add up to 100 wt .-% total. Components according to claim 1 to 7, characterized in that the application thickness of the adhesive (adhesive layer) is on the insulation boards 2 to 80 mm. Components according to claim 1 to 8, characterized in that the reinforcement protrudes 5 to 500 mm from the adhesive layer. Use of the components according to claim 1 to 9 for the production of formwork. Use of the components according to claim 1 to 9 or the formwork of claim 10 for the production of structures, such as walls, floors, ceilings or building structures.

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