DE19639143A1 - Method of making composite noise damping building panel - Google Patents

Method of making composite noise damping building panel

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Publication number
DE19639143A1
DE19639143A1 DE19639143A DE19639143A DE19639143A1 DE 19639143 A1 DE19639143 A1 DE 19639143A1 DE 19639143 A DE19639143 A DE 19639143A DE 19639143 A DE19639143 A DE 19639143A DE 19639143 A1 DE19639143 A1 DE 19639143A1
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Prior art keywords
pore
layer
open
closed
pore layer
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DE19639143A
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German (de)
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DE19639143C2 (en
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Ed Zueblin AG
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Ed Zueblin AG
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Priority to DE19639143A priority Critical patent/DE19639143C2/en
Priority to DE19710938A priority patent/DE19710938A1/en
Publication of DE19639143A1 publication Critical patent/DE19639143A1/en
Application granted granted Critical
Publication of DE19639143C2 publication Critical patent/DE19639143C2/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/082—Producing shaped prefabricated articles from the material by vibrating or jolting combined with a vacuum, e.g. for moisture extraction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/006—Pressing by atmospheric pressure, as a result of vacuum generation or by gas or liquid pressure acting directly upon the material, e.g. jets of compressed air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0067—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability making use of vibrations
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01F—ADDITIONAL WORK, SUCH AS EQUIPPING ROADS OR THE CONSTRUCTION OF PLATFORMS, HELICOPTER LANDING STAGES, SIGNS, SNOW FENCES, OR THE LIKE
    • E01F8/00—Arrangements for absorbing or reflecting air-transmitted noise from road or railway traffic
    • E01F8/0005—Arrangements for absorbing or reflecting air-transmitted noise from road or railway traffic used in a wall type arrangement
    • E01F8/0029—Arrangements for absorbing or reflecting air-transmitted noise from road or railway traffic used in a wall type arrangement with porous surfaces, e.g. concrete with porous fillers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/026—Porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/028—Treatment by energy or chemical effects using vibration, e.g. sonic or ultrasonic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/06—Concrete
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8414—Sound-absorbing elements with non-planar face, e.g. curved, egg-crate shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
    • E04B2001/848—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element
    • E04B2001/849—Groove or slot type openings

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Civil Engineering (AREA)
  • Electromagnetism (AREA)
  • Fluid Mechanics (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Building Environments (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

The method involves attaching a non-porous material (1) or closed porous material to a porous layer. The non-porous layer at least is of hardenable material. The open porous layer (2) can be sealed against the air. The as yet unhardened closed porous material is placed over the open porous material and the open porous layer is pre-prepared. The non-porous layer can be applied using low pressure. A sealing support layer (8) can be attached to the opposite side of the porous material to allow suction force to be applied through the porous material to the non-porous covering material.

Description

Es sind in der Anwendung als Lärmschutzwand Platten bekannt, die aus einem tragenden Teil, meistens Beton, und einem schallabsorbierenden Teil, meistens porigem Beton, bestehen. Die Fertigung dieser Platten geschieht z. B. dergestalt, daß zunächst der porige Beton in eine liegende Schalung eingebracht wird. Auf diese Schicht wird frisch auf frisch, also im noch nicht abgebundenen Zustand, der Beton der Trageplatte aufgegossen. Nach Erhärten der Massen wird die Schalung entfernt. Auf solche Weise hergestellte Lärmschutzwände weisen immer wieder eine schlechte Haftung der Schallabsorptionsschicht zur Tragwand auf, so daß es sogar zum Abfallen der Schallabsorptionsschicht kommen kann. Der Grund hierfür ist u. a. im Überdruck der Luftporen infolge des Aufbetonieren des Tragbetons zu suchen: Beim Aufbetonieren auf den Porenbeton entsteht eine gewisse Verdichtung des Porenbetons. Die dabei eingeschlossene Luft kann durch den darüberliegenden Tragbeton nicht entweichen. Dabei bildet sich an der Grenzschicht der beiden übereinandergeschichteten Massen eine Zone, in der Luftporen in den Tragbeton eindringen und im Porenbeton größere Poren entstehen, die eine Schwächezone bilden. Es ist üblich, den Tragbeton durch Rütteln zu verdichten.There are known plates in use as a noise barrier, which consist of a load-bearing part, mostly concrete, and a sound-absorbing part, mostly porous concrete. The manufacture of these plates happens for. B. such that the porous concrete is first placed in a horizontal formwork. To this The layer becomes fresh on fresh, that is, in the as yet un-set state, the concrete poured onto the support plate. After the masses have hardened, the formwork is removed. Noise barriers produced in this way always have a bad one Adhesion of the sound absorption layer to the support wall, so that it even for The sound absorption layer can come off. The reason for this is a. in the Overpressure of the air pores due to the concreting of the concrete: Concreting onto the aerated concrete creates a certain compression of the Aerated concrete. The trapped air can pass through the overlying air Do not allow the concrete to escape. This forms at the boundary layer of the two superimposed masses a zone in which air pores in the supporting concrete penetrate and larger pores arise in the aerated concrete, which is a weak zone form. It is common to compact the base concrete by shaking it.

Dadurch wird allerdings das Problem eines geringen Überdruckes der eingeschlossenen Luft ausgelöst.However, this eliminates the problem of low overpressure trapped air triggered.

Um den Verbund zwischen Tragbeton und schallabsorbierendem Material zu verbessern, wird daher erfindungsgemäß vorgeschlagen, das Auftreten von schwächenden Luftblasen in der Übergangszone durch Beaufschlagung des Porenbetons mit Unterdruck zu beseitigen, wobei die aufliegende noch flüssige spätere Trageschicht als selbstdichtende Absperrung gegen einen Lufteintritt von oben dient.To ensure the bond between the supporting concrete and sound absorbing material improve, it is therefore proposed according to the invention, the occurrence of debilitating air bubbles in the transition zone by applying the Eliminate aerated concrete with negative pressure, with the overlying still liquid Subsequent base layer as a self-sealing barrier to prevent air from entering serves above.

Dabei sieht das Verfahren das Ausbreiten des Unterdrucks im offenporigen Material innerhalb einer Schalung vor, die mit Saugstutzen zum Abziehen der Luft versehen ist. Das geschlossenporige/nichtporige Material für die Tragschicht wird wie erläutert auf diese offenporige Schicht aufgebracht. Schon vor, während oder aber auch erst nach dem Aufbringen der Tragschicht wird das offenporige (z. B. schallabsorbierende) Material über die Saugstutzen mit Unterdruck beaufschlagt. Die zwischen Tragschicht und offenporiger Schicht (z. B. Schallabsorptionsschicht) befindliche Luft wird dabei durch die offenporige Schicht hindurch abgesaugt. Dadurch können die Feinanteile der noch flüssigen Tragschicht in die obere Zone der offenporigen Schicht eindringen und einen sehr guten Verbund zwischen den beiden Schichten erzeugen. Durch die innige Durchdringung der beiden Schichten im Grenzbereich, die zusätzlich zur chemischen und adsorptiven Anbindung über die große Oberfläche eine starke mechanische Kopplung darstellt (ähnlich Haken und Ösen), ist es auch möglich Materialien miteinander zu verbinden, die normalerweise bei glatter Berührungsfläche nur eine schlechte Haftung aufweisen, z. B. Kunststoff und Beton. Es ist daher auch möglich, z. B. in einen Porenbeton zusätzlich Styroporpartikel einzumischen und diesen sehr luftigen Werkstoff dennoch ausreichend fest mit einer Tragschicht zu verbinden. Auch ist es möglich, durch Einlegen von Blöcken, Stäben oder anderen Formen aus lufthaltigen Materialien wie z. B. Styropor zwischen offenporiger Schicht und Tragschicht "Hohlräume" für eine weiter verbesserte Schallabsorption zu schaffen, ohne die Verbindung zwischen den beiden Schichten so zu schwächen, daß ein Abfallen zu befürchten wäre. Durch das ständige Absaugen am offenporigen Material ist auch kein großer Unterdruck erforderlich, so daß billige Pumpen eingesetzt werden können. Als schon geeignet erweisen sich außen angelegte Unterdrücke, die größenordnungsmäßig 0,1 bis 0,5 Atmosphären (100 bis 500 Hektopascal/Quadratmeter) betragen. Dabei lastet auf der Tragschicht bereits ein zusätzlicher Druck von 0,1 bis 0,5 Atmosphären, der die noch flüssige Tragschicht in die nun entlüfteten Poren preßt. (Das Eigengewicht der Tragschicht trägt demgegenüber nur zu einem Druck von größenordnungsmäßig 0,03 Atmosphären (30 Hektopascal/Quadratmeter) zum Druck auf die Grenzschicht bei!). The process involves spreading the negative pressure in the open-pore material within a formwork that is equipped with suction ports to extract the air. The closed-pore / non-pore material for the base layer is applied to this open-pore layer as explained. The open-pore (e.g. sound-absorbing) material is subjected to negative pressure via the suction ports even before, during or only after the base layer has been applied. The air between the base layer and the open-pore layer (e.g. sound absorption layer) is extracted through the open-pore layer. As a result, the fine fractions of the still liquid base layer can penetrate into the upper zone of the open-pore layer and produce a very good bond between the two layers. Due to the intimate penetration of the two layers in the border area, which, in addition to the chemical and adsorptive connection via the large surface, represents a strong mechanical coupling (similar to hooks and eyes), it is also possible to connect materials that are normally only poor with a smooth contact surface Have liability, e.g. B. plastic and concrete. It is therefore also possible, for. B. additionally mix polystyrene particles in a cellular concrete and yet connect this very airy material sufficiently firmly with a base layer. It is also possible to insert blocks, rods or other shapes made of air-containing materials such as. B. Styrofoam between open-pore layer and base layer to create "cavities" for a further improved sound absorption without weakening the connection between the two layers so that a fall would be feared. Due to the constant suction on the open-pored material, no great vacuum is required, so that cheap pumps can be used. External pressures, which are of the order of 0.1 to 0.5 atmospheres ( 100 to 500 hectopascals / square meter), have already proven to be suitable. An additional pressure of 0.1 to 0.5 atmospheres already acts on the base layer, which presses the still liquid base layer into the now vented pores. (In contrast, the dead weight of the base layer only contributes to a pressure of the order of 0.03 atmospheres ( 30 hectopascals / square meter) to the pressure on the boundary layer!).

Da der durch das Absaugen erzeugte Druck auf die Grenzschicht den durch das Eigengewicht der obenliegenden Schicht erzeugten Druck bei weitem übersteigt, ist es in einer weiteren Ausführung des Verfahrens auch möglich, die porige Schicht auf die geschlossenporige/nichtporige Schicht zu legen. Die geschlossenporige/ nichtporige Schicht liegt dann in einer nach unten und zu den Seiten geschlossenen Schalung. Die auf ihr befindliche porige Schicht ist in diesem Fall mit einem durch den Luftdruck verformbaren, die gesamte Schalung gegen Luftzutritt abdichtenden Medium (z. B. einer Kunststoffplane oder einer sich bei Absaugung der Luft anpressenden Formschalung), an dem sich Absaugstutzen zur Beaufschlagung mit Unterdruck befinden, abgedeckt. Die noch nicht ausgehärtete geschlossenporige oder nichtporige Schicht wird dann durch das Absaugen an der oberen porigen Schicht in die nun entlüfteten Poren nach oben gepreßt.Since the pressure generated by the suction on the boundary layer by the The weight of the layer above the pressure generated by far exceeds in a further embodiment of the method it is also possible to apply the porous layer to lay the closed-pore / non-pore layer. The closed-pore / non-porous layer is then in a closed down and to the sides Formwork. The porous layer on it is in this case with a through Deformable air pressure, sealing the entire formwork against air ingress Medium (e.g. a plastic tarpaulin or one that is sucked out of the air pressing formwork), on which there are suction nozzles for loading Vacuum are covered. The not yet hardened closed-pore or non-porous layer is then sucked in on the upper porous layer the now vented pores are pressed upwards.

Die Beaufschlagung mit Unterdruck kann, je nach Grad der Offenporigkeit, auf verschiedene Weisen erfolgen:The application of negative pressure can, depending on the degree of open porosity There are different ways:

1. Fall1st case

Die porige Schicht ist unten, die nichtporige oder geschlossenporige oben: Bei sehr offenporigen Dämmschichten ist es möglich, seitlich am Rande der Schalung abzusaugen, wie es in Fig. 1a dargestellt ist. Die aufliegende Tragschicht bildet die Abdichtung gegen die Luft und der Unterdruck breitet sich bis in die Mitte der Form aus. Der Vorteil dieser Anordnung ist ihre Einfachheit in der Konstruktion, da nirgendwo Bauteile verwendet werden, die hohe Unterdrücke aushalten müssen. Bei weniger offenporigen Dämmschichten treten gemäß Ausführungsbeispiel nach Fig. 1a Schwierigkeiten auf, den Unterdruck an alle Bereiche der Grenze offenporige/geschlossenporige (nichtporige) Schicht zu leiten. Hier ist eine aufwendigere Konstruktion nötig, bei der an mehreren Stellen an der Unterseite zusätzliche Absaugstutzen vorhanden sind, wie in Fig. 1b, oder das offenporige Material auf eine Siebplatte ausgebracht wird, durch die es gerade nicht mehr hindurchfließt. Diese Siebplatte bildet die Decke eines Hohlraumes, der nun mit Unterdruck beaufschlagt wird (siehe Fig. 2). Bei großen Flächen muß die Siebplatte auf Stützen abgestützt sein, um ein Durchbiegen der Siebplatte zu verhindern. In einer einfacheren Ausführung wird der Hohlraum, durch den hindurch abgesaugt wird, durch ein poriges, unter dem porigen Material befindliches Gut (z. B. Vlies, Steinwolle, Röhrensystem) ersetzt, welches nach Aushärten der Schichten entfernt wird, wenn es nicht sogar an Ort und Stelle verbleiben kann. Die Absaugung kann je nach Offenporigkeit entweder nur seitlich (s. Fig 3a) oder auch zusätzlich an weiteren Stellen an der Unterseite erfolgen (siehe Fig. 3b).The porous layer is at the bottom, the non-porous or closed-pore layer at the top: In the case of very open-pored insulation layers, it is possible to vacuum off at the side of the formwork, as shown in FIG. 1a. The overlying base layer forms a seal against the air and the negative pressure spreads to the center of the mold. The advantage of this arrangement is its simplicity in construction, since no components are used anywhere that have to withstand high negative pressures. In the case of less open-pore insulation layers, according to the exemplary embodiment according to FIG. 1a, difficulties arise in directing the negative pressure to all areas of the boundary of open-pore / closed-pore (non-pore) layer. Here, a more complex construction is necessary, in which additional suction ports are provided at several points on the underside, as in FIG. 1b, or the open-pore material is applied to a sieve plate through which it is no longer flowing. This sieve plate forms the ceiling of a cavity which is now subjected to negative pressure (see Fig. 2). With large areas, the screen plate must be supported on supports to prevent the screen plate from bending. In a simpler embodiment, the cavity through which suction is carried out is replaced by a porous material located under the porous material (e.g. fleece, rock wool, tube system), which is removed after the layers have hardened, if not even at all Can remain in place. Depending on the open porosity, the suction can either only take place on the side (see FIG. 3 a) or additionally at other points on the underside (see FIG. 3 b).

In einer weiteren Ausführungsmöglichkeit des Verfahrens wird die offenporige Schicht erst ausgehärtet. Anschließend wird sie selbst (bei großen Flächen durch Stützen abgestützt) als Decke des Hohlraums eingesetzt, unter dem abgesaugt wird. Da die Schicht ausgehärtet ist, ist keine Siebplatte mehr vonnöten. Auch die feste offenporige Schicht kann selbstverständlich über Vlies, Steinwollmatten, Rohrsysteme oder ähnliche Absaughilfsmittel mit Unterdruck beaufschlagt werden.In a further embodiment of the method, the open-pore layer only hardened. Then it becomes itself (with large areas by supports supported) used as the ceiling of the cavity under which suction is carried out. Since the Layer has hardened, a sieve plate is no longer required. Of course, the solid open-pore layer can also be Rock wool mats, pipe systems or similar suction aids with negative pressure be charged.

Es muß darauf hingewiesen werden, daß selbst im Falle eines schlechteren Ausbreitens des Unterdrucks im porigen Material die einfache Anordnung gemäß Fig. 1a oft ausreichende Ergebnisse liefert, da der durch den Unterdruck erzeugte starke Verbund der beiden Schichten am Rande der Schalung bzw. an anderen Stellen punktueller Absaugung bereits ausreichend ist, die gesamte Platte zu stabilisieren (das porige Material ist dann gewissermaßen wie in einem Rahmen an der Tragschicht befestigt).It must be pointed out that even in the event of a poorer spreading of the vacuum in the porous material, the simple arrangement according to FIG. 1a often yields sufficient results, since the strong bond between the two layers at the edge of the formwork or at other points produced by the vacuum selective suction is already sufficient to stabilize the entire plate (the porous material is then attached to the base layer as if in a frame).

2. Fall2nd case

Die porige Schicht ist oben, die geschlossenporige/nichtporige unten:
In diesem Fall kann das Verfahren in einer Anordnung erfolgen, die den auf den Kopf gestellten Fig. 1a, b oder 3a, b entspricht, aber nach unten durch einen zusätzlichen Schalungsboden abgedichtet ist (siehe exemplarisch Fig. 4 als gedrehte Fig. 1a), und bei der eine über der porigen Schicht befindliche luftdichte Abdeckung eine Verformbarkeit oder Verschiebbarkeit aufweist, so daß sie beim Absaugen über Absaugstutzen, die sich an der Schalung und/oder an der Abdeckung befinden, angepreßt wird, wodurch die untere noch nicht erhärtete nichtporige/ge­ schlossenporige Schicht in die nächstliegenden entlüfteten Poren gepreßt wird.The porous layer is at the top, the closed-pore / non-porous at the bottom:
In this case, the method can be carried out in an arrangement which corresponds to the upside-down FIGS . 1a, b or 3a, b, but is sealed at the bottom by an additional formwork floor (see, by way of example, FIG. 4 as a rotated FIG. 1a), and in which an airtight cover located over the porous layer has a deformability or displaceability, so that it is pressed during suction via suction nozzles, which are located on the formwork and / or on the cover, whereby the lower, not yet hardened, non-porous / ge closed-pore layer is pressed into the nearest vented pores.

Obwohl das Verfahren hier am Beispiel einer Lärmschutzwand erläutert wurde, so ist es doch nicht auf die Herstellung einer solchen beschränkt.Although the method was explained here using the example of a noise barrier, it is it is not limited to the production of one.

So ist es durchaus möglich, mit dem Verfahren jedwedes offenporige Material an eine geschlossenporige oder nichtporige aushärtbare Trageschicht anzubinden. Die Erzeugung eines Verbundes zwischen offenporigen und geschlossenporigen/nichtporigen Schichten ist so z. B. auch wünschenswert zur Erzeugung von Betonfertigbauteilen für Häuser, die hohe Wärmedämmung aufweisen sollen. Eine porige Schicht (z. B. Styropor in Porenbeton) übernimmt dabei bereits einen Teil der Wärmeisolation.So it is quite possible to use the process to open-pore material to connect closed-pore or non-pore hardenable base layer. The creation of a bond between open pore and closed-pore / non-pore layers is so z. B. also desirable for Production of prefabricated concrete components for houses that have high thermal insulation should. A porous layer (e.g. polystyrene in aerated concrete) already takes over part of the thermal insulation.

Eine weitere Einsatzmöglichkeit für nach dem beschriebenen Verfahren hergestellte Verbundschichten großer Haftung sind z. B. auch porige Trägerschichten (große Oberfläche!) für Katalysatoren an einer tragenden Kunststoffmatrix.Another possible application for those produced by the described method Composite layers of great adhesion are e.g. B. also porous carrier layers (large Surface!) For catalysts on a load-bearing plastic matrix.

Eine weitere Möglichkeit ist die Herstellung eines schalldämpfenden schotterlosen Oberbaus, bei dem auf die Feste Fahrbahn Porenbeton aufgebracht wird, wodurch die Fahrgeräusche gedämpft werden. Die Produktion kann hier direkt vor Ort und kontinuierlich mit oberer und seitlicher Absaugung über an einem abdeckenden Medium befindliche Absaugstutzen erfolgen.Another possibility is the production of a sound absorbing ballastless Superstructure in which aerated concrete is applied to the slab track, whereby the driving noises are dampened. Production can take place here on site and continuously with top and side suction over a covering There are medium suction ports.

BezugszeichenlisteReference list

1 geschlossenporige oder nichtporige Tragschicht
2 offenporige Schicht
3 Luftabsaugstutzen
4 Schalung
5 Hohlraum
6 Stütze
7 Platte mit Öffnungen zum Luftabsaugen
8 Material mit hohem Luftdurchtrittswert
9 Abdeckung, die sich nach Beaufschlagung der offenporigen Schicht mit Unterdruck an die offenporige Schicht anpreßt. 1 closed-pore or non-pore base layer
2 open-pore layer
3 air extraction sockets
4 formwork
5 cavity
6 support
7 Plate with openings for air extraction
8 Material with high air permeability
9 Cover that presses against the open-pore layer after applying pressure to the open-pore layer.

Claims (14)

1. Verfahren zur Herstellung einer Verbundwerkstoffplatte aus einer offenporigen und einer geschlossenporigen oder nichtporigen Schicht, von der mindestens die geschlossenporige/nichtporige Schicht aus einem aushärtbaren Material gebildet wird, dadurch gekennzeichnet, daß die offenporige Schicht mit der sich nach oben gegen die Luft selbst abdichtenden, noch nicht ausgehärteten geschlossenporigen/ nichtporigen Schicht überschichtet wird und die offenporige Schicht schon vor, während oder auch erst nach Aufbringen der geschlossenporigen/nichtporigen Schicht mit Unterdruck beaufschlagt wird.1. A process for the production of a composite sheet from an open-pore and a closed-pore or non-pore layer, of which at least the closed-pore / non-pore layer is formed from a hardenable material, characterized in that the open-pore layer with the self-sealing upward against the air, the non-hardened closed-pore / non-pore layer is overlaid and the open-pore layer is subjected to negative pressure before, during or only after application of the closed-pore / non-pore layer. 2. Verfahren zur Herstellung einer Verbundwerkstoffplatte aus einer offenporigen und einer geschlossenporigen oder nichtporigen Schicht, von der mindestens die geschlossenporige/nichtporige Schicht aus einem aushärtbaren Material gebildet wird, dadurch gekennzeichnet, daß die noch nicht erhärtete nichtporige/geschlossenporige Schicht in einer Schalung mit der offenporigen Schicht überschichtet wird, auf die offenporige Schicht ein verformbares Medium, das Absaugstutzen aufweist, so aufgelegt und angebracht wird, daß porige Schicht sowie geschlossenporige/nichtporige Schicht gegen die äußere Luft hinreichend abgedichtet sind und die offenporige Schicht über die am aufliegenden Medium befindlichen Absaugstutzen mit Unterdruck beaufschlagt wird.2. Process for producing a composite panel from an open-pore and a closed-pore or non-pore layer, of which at least the closed-pore / non-pore layer is formed from a curable material, characterized in that the not yet hardened non-porous / closed-pore Layer in a formwork is covered with the open-pore layer on which open-pore layer a deformable medium, which has suction nozzle, so is placed and attached that porous layer as well closed-pore / non-pore layer sufficiently sealed against the outside air are and the open-pore layer over the existing on the medium Suction nozzle is subjected to negative pressure. 3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß das Medium eine Kunststoffplane oder eine durch den beim Absaugen entstehenden Unterdruck hinreichend angepreßte verformbare Schalung ist.3. The method according to claim 2, characterized in that the medium is a plastic tarp or by the vacuum created during suction sufficiently deformable Formwork is. 4. Verfahren nach mindestens einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die offenporige Schicht noch nicht ausgehärtet ist und wenigstens an einigen Stellen benachbart zu einem Mittel liegt, welches dem an diesem Mittel beaufschlagten Unterdruck erlaubt, in Bereiche an der Grenzschicht Mittel/offenporige Schicht vorzudringen, von wo aus der Unterdruck in der Lage ist, sich, wenn auch abgeschwächt, durch die offenporige Schicht hindurch bis zu allen Bereichen der Grenzschicht zwischen offenporiger und geschlossenporiger/nicht­ poriger Schicht fortzupflanzen.4. The method according to at least one of claims 1 to 3,  characterized in that the open-pore layer is not yet cured and is at least in some places adjacent to an agent that is related to the this medium allows negative pressure to be applied to areas at the boundary layer To penetrate the middle / open-pore layer, from where the negative pressure is able to even though weakened, through the open-pore layer to everyone Areas of the boundary layer between open-pore and closed-pore / not propagate porous layer. 5. Verfahren nach mindestens einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß das Mittel eine luftgefüllte Hohlräume enthaltende Matte oder ein mit Löchern versehenes Rohrsystem ist oder durch eine siebartige Platte gebildet wird, die, falls nötig abgestützt, die Decke eines Hohlraumes bildet, der mit Unterdruck beaufschlagt wird.5. The method according to at least one of claims 1 to 4, characterized in that the agent contains air-filled cavities Mat or a perforated pipe system or by a sieve-like Plate is formed which, if supported, forms the ceiling of a cavity which is subjected to negative pressure. 6. Verfahren nach mindestens einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß nur an mindestens einer der Seiten der offenporigen Schicht abgesaugt wird.6. The method according to at least one of claims 1 to 5, characterized in that only on at least one of the sides of the open-pore Layer is suctioned off. 7. Verfahren nach mindestens einem der Ansprüche 1 und 4 bis 6, dadurch gekennzeichnet, daß die offenporige Schicht bereits ausgehärtet ist, wenn die noch nicht ausgehärtete geschlossenporige/nichtporige Schicht aufgebracht wird, und die offenporige Schicht, im Bedarfsfall auf Stützen gelagert, die Decke eines Hohlraumes bildet, der mit Unterdruck beaufschlagt wird.7. The method according to at least one of claims 1 and 4 to 6, characterized in that the open-pore layer is already cured when the not yet hardened closed-pore / non-pore layer is applied, and the open-pore layer, supported on supports if necessary, the ceiling of one Forms cavity, which is subjected to negative pressure. 8. Verfahren nach mindestens einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß die offenporige Schicht bereits ausgehärtet ist, wenn die noch nicht ausgehärtete geschlossenporige/nichtporige Schicht aufgebracht wird, oder, gemäß Anspruch 2 und 3, die offenporige auf die geschlossenporige/nichtporige Schicht aufgebracht wird, und daß die offenporige Schicht benachbart zu einem Mittel nach Anspruch 4 und Anspruch 5 ist, welches dem an diesem Mittel beaufschlagten Unterdruck erlaubt, in Bereiche an der Grenzschicht Mittel/offenporige Schicht vorzudringen, von wo aus der Unterdruck in der Lage ist, sich, wenn auch abgeschwächt, durch die offenporige Schicht hindurch bis zu allen Bereichen der Grenzschicht zwischen offenporiger und geschlossenporiger/nichtporiger Schicht fortzupflanzen.8. The method according to at least one of claims 1 to 7, characterized in that the open-pore layer is already cured when the not yet hardened closed-pore / non-pore layer is applied, or, according to claims 2 and 3, the open-pore to the closed-pore / non-pore  Layer is applied, and that the open-pore layer adjacent to an agent according to claim 4 and claim 5, which is applied to this means Negative pressure allowed, in areas at the middle / open-pore boundary layer to penetrate from where the negative pressure is able, even if weakened, through the open-pore layer to all areas of the Boundary layer between open-pore and closed-pore / non-pore layer reproduce. 9. Verfahren nach mindestens einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, daß in die Grenzschicht zwischen offenporiger und geschlossenporiger/nichtporiger Schicht ein oder mehrere Gegenstände eingebracht werden.9. The method according to at least one of claims 1 to 8, characterized in that in the boundary layer between open-pore and closed-pore / non-pore layer one or more objects introduced will. 10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, daß die in die Grenzschicht zwischen offenporiger und geschlossenporiger/nichtporiger Schicht eingebrachten Gegenstände die Schallabsorption oder das Wärmeisoliervermögen verbessern.10. The method according to claim 9, characterized in that in the boundary layer between open pore and closed-pore / non-pore layer introduced objects Improve sound absorption or thermal insulation. 11. Verfahren nach mindestens einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, daß die geschlossenporige/nichtporige aushärtbare Schicht aus einem Beton besteht.11. The method according to at least one of claims 1 to 10, characterized in that the closed-pore / non-pore curable layer consists of a concrete. 12. Verfahren nach mindestens einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, daß die offenporige Schicht aus einem Porenbeton besteht.12. The method according to at least one of claims 1 to 11, characterized in that the open-pore layer consists of a cellular concrete. 13. Verfahren nach mindestens einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, daß die offenporige Schicht außer Poren, eventuellen Hartkomponenten und Bindemittel auch noch größenordnungsmäßig bis zu 50% Volumenanteil andere stark lufthaltige Komponenten, z. B. Styroporpartikel, enthält. 13. The method according to at least one of claims 1 to 12, characterized in that the open-pore layer except pores, any Hard components and binders even up to 50% Volume fraction of other high-air components, e.g. B. styrofoam particles.   14. Lärmschutzwand, die nach dem beanspruchten Verfahren hergestellt wird.14. Noise barrier made by the claimed method becomes.
DE19639143A 1996-09-24 1996-09-24 Process for the production of composite panels from open-pore and closed-pore or non-pore-curing materials Expired - Fee Related DE19639143C2 (en)

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DE19639143C2 (en) 2001-06-28

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