DE19947216A1 - Production of a sturdy wall element comprises forming a sturdy flat square-shaped core part, adhering a cardboard layer swollen using adhesive to both sides of the main surfaces of the core part; and leaving to dry to bind the adhesive - Google Patents

Abstract

Production of a sturdy wall element comprises forming a sturdy flat square-shaped core part (2) of the element made of a mineral lightweight concrete material, preferably porous concrete material having vertical hollow chambers (4); adhering a cardboard layer (7, 8) swollen using adhesive to both sides of the main surfaces (5, 6) of the core part; and leaving to dry to bind the adhesive. An Independent claim is also included for the wall element produced by the process. Preferred Features: The main surfaces of the core part are provided with adhesive before applying the adhesive.

Description

The invention relates to a method for producing a solid wall Elements for dry interior finishing and a produced accordingly Wall element.

For modern interior design in both new and old buildings Building renovation, two common wall systems are known, namely on the one hand so-called plasterboard stud walls and on the other hand so-called pores concrete element panels.

Plasterboard walls have the advantage that their room-side wall surface is very smooth and can be installed relatively quickly and efficiently are. However, this wall system is liable - especially in the area of private housing - the flaw that the wall due to their hollow knocking noise is commonly referred to as "cardboard cover wall" and is not very popular due to its lack of massive character.

Remedies in this regard are also available on the market chen gas or aerated concrete elements, either as storey-high Partition elements or large compared to conventional bricks format partition walls are executed. These gas concrete elements give the impression of a solid wall and can like usual che walls with conventional dowels for fastening furniture parts etc. serve, but they also have a number of disadvantages. So are the elements are relatively heavy, which u. a. on their flat area reinforcement is provided, which is provided for reasons of stability  have to be. The reinforcement is made of steel and must be due to the porosity of gas concrete are protected against corrosion. The reinforcement is relative expensive. When processing the gas concrete elements, the throws Reinforcement also on the problem that when sawing the Elements, for example, for fitting the elements in sloping ceilings must be severed. Therefore, simple saws cannot be used on this Purpose.

Furthermore, these gas concrete elements are on their room-side surface not ready for papering, but after assembly must still with a Apply primer and cover with a thin filler. After all, the laying of cables in a wall from such gas Concrete elements are expensive because the corresponding slots are milled Need to become.

Based on the described disadvantages of the prior art the invention has for its object a method for producing a massive wall element for dry interior construction and a corre accordingly produced wall element to indicate that without sacrificing its Stability is very lightweight and ready to be papered.

The solution to this problem is from a process engineering point of view Claim 1 and in terms of device technology by the claim 10 given.

Accordingly, the backbone of the wall element consists of a solid, flat, rectangular core made from a mineral lightweight concrete material al. preferably for vertical weight reduction with a vertical one  Cavities is provided. The lightweight concrete preferably consists of a AAC material. On the main surfaces of the core part on the room side Lightweight concrete is glued on both sides of the cardboard layers, through the adhesive application has swollen. Then the cardboard layer let dry while setting the adhesive application.

A particular gimmick in the present invention lies in the first hend the mentioned cardboard layer in swollen condition. By the swelling expands the cardboard material. By sticking in this condition the cardboard layer is in a kind of stretched closed got up on the core part. When the glue dries, it pulls out Cardboard layer together again and becomes mirror-smooth. After the restlo The cardboard layers applied in this way are drying out of the element tense and cause the element to be preloaded. It will be there due to very rigid and stable, which means that the state of the art existing reinforcement can be omitted. The cardboard layer is practicing with the inventor wall element produced according to a typical double function. On the one hand, it ensures that the surface is ready to paper che of the wall element. On the other hand, it contributes significantly to the stability of the Wall element at. The elimination of the necessary in the prior art Reinforcement also enables the vertical to pass through without any problems Provide cavities, which in turn are used for problem-free installation cable and other house installations can, but on the other hand not disturb the massive character of the wall.

Preferred embodiments of the method and corresponding wall element can be found in the dependent claims bar. To explain the corresponding features and their advantages  reference is made to the following description in which an exec Example of the invention with reference to the accompanying drawings is discussed. Show it

Fig. 1 shows a vertical section through a wall element and

Fig. 2 is a schematic perspective view of a molding device for a plurality of wall elements in an intermediate production step.

As is clear from Fig. 1, the wall element 1 has a solid core part 2 , which consists of a structure-sealed cellular concrete with a dry bulk density of z. B. 400 kg / m ³ . The core part 2 is centered on its central longitudinal plane 3 with vertically continuous, lined-up zy-cylindrical cavities 4 , which serve to drastically lighten the weight of the wall element and for easy installation of technical components. The flat cuboid core part 2 has dimensions that are matched to the interior - that is, the setting of partition walls. For example, the width b can be 62.5 cm, the thickness d 10 cm and the height 262.5 cm - i.e. floor height.

On the two main surfaces 5 , 6 of the core part 2 on the room side, cardboard layers 7 , 8 are glued in a manner to be explained in more detail. After drying the adhesive, these form a very smooth and pre-tensioned outer surface 9 , 10 of the wall element 1 , which can be papered immediately. On these outer surfaces 9 , 10 , the cardboard layers 7 , 8 are also hydrophobic and embedded with a flame-retardant coating.

The main surfaces 5 , 6 of the core part 2 of the wall element 1 are provided on their vertical side edges 11 with a flat recess 12 , the contour of which follows the cardboard layer 7 , 8, respectively. In the depression thus formed, a reinforcing tape can be glued in each case when processing the wall elements to form a wall at the joints and then filled with a spatula to form a crack bridge.

The manufacturing process for the wall elements 1 is to be explained with reference to FIG. 2:
The starting point is an open-top molding box 13 with a Bo 14 , two longitudinal side walls 15 , 16 and so-called longitudinal shutters 17 , of which only one is recognizable in FIG. 2. The transverse dimension Q of the molded box 13 corresponds to a multiple - for example five times - the thickness d of the wall elements 1 . The height H of the molding box corresponds to the width b of the wall elements 1 , the distance between the two longitudinal racks 17 corresponds to the height of the wall elements 1 , so it is, for example, the specified 262.5 cm. The longitudinal racks 17 are provided with a regular grid of circular bearing openings 18 in which core tubes 19 are seated. These duri fen through the molding box 13 and serve to form the ver tical cavities 4 in the wall elements.

After upgrading the molding box 13 in the manner mentioned above, the aforementioned mineral aerated concrete is poured in, for example from lime, quartz sand and water with the addition of a foaming agent and other conventional auxiliaries in the production of concrete. The molding box 13 is then briefly shaken and the aerated concrete 20 compacted. After a certain dwell time of the aerated concrete 20 in the molding box, the material is sufficiently stiffened so that the core tubes 19 can be pulled by hand or by machine. For better detachment of the core pipes 19 from the aerated concrete material 20 , these can be turned on briefly. In order to shorten the residence time of the cellular concrete 20 in the molding box 13 , the molding box 13 can be heated from the outside and via the hollow core tubes 19 . If the aerated concrete sets exothermically, cooling can also be carried out via the core tubes 19 in order to avoid excessive heating. About the core tubes 19 can be tempered with the help of the appropriate temperature control fluid, such as heating steam, cooling water or the like, the aerated concrete material.

After demoulding, a voluminous block B of aerated concrete material remains, which is then sawn into the individual core parts 2 to form the individual core parts 2 along the saw lines indicated by dash-dotted lines in FIG. 2. The core parts thus produced are already very precisely dimensioned and very smooth on their main surfaces 5 , 6 , which represent the sawing surfaces. After sawing, the jumps 12 are introduced at the side edges 11 of the core parts 2 by means of a suitable milling machine.

To stick the two cardboard layers 7 , 8 on the main surfaces 5 , 6 of the core parts 2 , the cardboard layers 7 , 8 are coated with an adhesive 21 (indicated in the enlarged detail of FIG. 1) or paste-like material. This adhesive 21 moistens the cardboard and causes it to swell and expand.

A cardboard layer 7 prepared in this way is glued in the smoothed state using pressure to the respective main surface 5 , 6 of the core part 2 in the smoothed state. The respective main surface 5 , 6 of the core part 2 was also provided with an adhesive coating before gluing.

To glue the cardboard layers 7 , 8 it should be added that the core part 2 can also be placed in reverse on a suitably prepared cardboard bed and pressed from above with the second cardboard layer.

By allowing the cardboard layers 7 , 8 to dry, which is supported by heating and can be shortened in time, the adhesive application sets. The cardboard layers 7 , 8 are then stably connected to the core part 2 , the cardboard layers 7 , 8 contracting again due to the drying process. This allows them - as already discussed - to be mirror-smooth and to build up a pre-tension in them, as a result of which the wall element 1 becomes very rigid and stable in the manner of a sandwich component.

As an alternative to the manufacture of the core part 2 , there is also the manufacture of lightweight bricks from aerated concrete material on a hollow block machine in the format z. B. 62.5 cm x 10 cm x 40 cm. This wall block-like light cuboid are glued with adhesive mortar to storey-high core parts 2 and then, after drying or immediately placed horizontally on a bed of a swollen cardboard layer 7 . The second cardboard layer 8 can then be pressed on from above.

Finally, the advantages of the Wandele elements 1 according to the invention can be summarized as follows:

• - Integrated empty pipe system
• - massive sound effect  
• - Immediate wallpapering ability
• - low weight
• - rational production
• - no reinforcement.

Claims (12)

1. Method for producing a solid wall element for dry interior construction, characterized by the following method steps:

• - Manufacture of a solid, flat cuboid, preferably with vertically continuous cavities ( 4 ) provided core part ( 2 ) of the wall element ( 1 ) from a mineral lightweight concrete material, preferably from aerated concrete material
• - Glue a cardboard layer ( 7 , 8 ) swollen by the adhesive application onto the two main surfaces ( 5 , 6 ) of the core part ( 2 ) on the room side, and
• - Allow the cardboard layers ( 7 , 8 ) to dry while setting the adhesive application.

2. The method according to claim 1, characterized in that the main surfaces ( 5 , 6 ) of the core part ( 2 ) are also provided with adhesive before gluing the respective cardboard layer ( 7 , 8 ). 3. The method according to claim 1 or 2, characterized in that the swollen cardboard layer ( 7 , 8 ) in the smooth state on the main surfaces ( 5 , 6 ) of the core part ( 2 ) are glued. 4. The method according to any one of claims 1 to 3, characterized in that the cardboard layers ( 7 , 8 ) under pressure on the main surfaces ( 5 , 6 ) are glued. 5. The method according to any one of claims 1 to 4, characterized in that the core parts ( 2 ) of the wall element ( 1 ) by casting a volume of several core parts ( 2 ) comprising block (B) made of lightweight concrete in a molding box ( 13 ), as well as subsequent stiffening or hardening and sawing the block (B) into individual core parts ( 2 ). 6. The method according to claim 5, characterized in that in the form box ( 13 ) a plurality of core tubes ( 19 ) are used to form the vertically continuous cavities ( 4 ). 7. The method according to claim 6, characterized in that the lightweight concrete material ( 20 ) in the molding box ( 13 ) is tempered by means of a tempering fluid flowing through the core tubes ( 19 ). 8. The method according to any one of claims 1 to 7, characterized in that the core parts ( 2 ) are made without reinforcement. 9. The method according to any one of claims 1 to 4, characterized in net that the core parts each from several prefabricated, wall block-like light cuboids are assembled. 10. Wall element for dry interior construction, produced according to a method according to one of claims 1 to 9, with

• - A solid, flat cuboid, preferably with vertically continuous cavities ( 4 ) provided core part ( 2 ) made of a mineral lightweight concrete material, preferably Porenbe clay material,

marked by

• - Each in a swollen state by adhesive application on the room-side main surfaces ( 5 , 6 ) of the core part ( 2 ) glued, pre-tensioned in the set state of the adhesive layer ( 7 , 8 ).

11. Wall element according to claim 10, characterized in that the cardboard layer ( 7 , 8 ) on the room-side outer surface ( 9 , 10 ) is hydrophobic and / or flame retardant. 12. Wall element according to claim 10 or 11, characterized in that the main surfaces ( 5 , 6 ) of the wall elements ( 1 ) are provided on their vertical side edges ( 11 ) with a flat recess ( 12 ) for receiving a reinforcing tape.