DE29623096U1 - Device for producing lightweight composite bricks and composite lightweight bricks made therewith - Google Patents

Description

Device for producing composite lightweight bricks and composite lightweight bricks produced thereby

The invention relates to a device for producing composite lightweight bricks of block-shaped or other form for constructing building parts, composed of parts of mainly insulating materials and mainly load-bearing materials, as well as composite lightweight bricks produced in this way.

In order to achieve both good thermal insulation and a relatively high compressive strength of bricks, it is generally known to produce hollow bricks. The aim is to minimize the load-bearing web thickness and thus increase the insulating hole proportion and extend the heat paths between the outer sides of the bricks. The larger the hole proportion, the smaller the compressive strength of the brick. There are also limits to the proportional increase in the hole proportion, as the brick blank loses its stability during production using the wet pressing process, which makes things particularly difficult when cutting the strand, stacking it and transporting it.

In addition, a brick with an extremely high percentage of holes can only be handled with high breakage losses and is uneconomical to lay because a not insignificant proportion of the mortar falls into the holes, which also reduces the thermal insulation capacity.

After the clay material has been prepared, if necessary with the porosity agents, using pan mills, rolling mill cascades, precision rolling mills and forced mixers, hollow bricks are manufactured in accordance with DIN 105 using the wet extrusion process. A clay strand is pressed using screw or roller presses through mouthpieces of different designs contoured with an appropriate external shape and equipped with hard metal or ceramic inserts.

The strand advance is controlled both by the design of the core holder frame and by variably adjustable brake plates on the outer and inner sides of the contour.
The final contour is pressed out over the entire
Area of the strand cross-section.

By adding a maximum amount of sawdust, paper sludge, straw, polystyrene and other porosity agents to the clay material, a further improvement in thermal insulation capacity is achieved, but this is also at the expense of the load-bearing capacity. The porosity agents burn during the brick firing process in the brick kiln and leave behind residues of smaller size, above-average porosity bars, for example in
Longitudinal, diagonal, inclined or other shapes are therefore only partially load-bearing.

For example, commercially available vertically perforated bricks for 30 mm masonry of external walls, which are very interesting from an economic point of view, do indeed comply with the thermal insulation values prescribed by the Thermal Insulation Ordinance, but do not fully meet the requirements in terms of their compressive strength.
Therefore, material- and cost-intensive, two- or multi-layer wall systems must be manufactured to ensure compliance with the compressive strength values required by building physics.

Furthermore, composite bricks are known, which are based on the connection
of brick, as at least partially load-bearing material, with
highly insulating materials.

These are special components such as roller shutter boxes,
Lintels or panels for special applications, which are constructed using a supporting structure made of brick material, possibly reinforced with steel and/or concrete, with thermally insulating materials such as expanded polystyrene or polyurethane
be completed.

Their production is usually carried out in complex individual production
and tailored to the respective special application.
Be a variety of prefabricated components in sandwich construction

In addition to a wide variety of materials, bricks are used at least as a façade to improve their appearance or to serve as a uniform plaster base.

In all of the above-mentioned applications, the brick material only partially assumes the load-bearing function, apart from the fact that the positive insulating properties of brick material can basically be used in every application.

The main disadvantage of these composite construction elements, which differ greatly from the positive material properties of bricks, is, in addition to the relatively low compressive strength, the poor water vapor diffusion behavior and the low heat storage capacity.

The problem of the invention is to demonstrate a composite lightweight brick which has the known positive properties of brick material, in particular with regard to compressive strength and thermal insulation capacity, to a high degree and combines this with low weight, and can be produced easily and with little effort even in large quantities.

The problem is solved with the device according to claim 1 and the composite lightweight brick according to claim 7. Using a not inconsiderable part of the machines and equipment used for preparation and assembly in traditional brick production, a composite lightweight brick with compressive strength classes 6 to 12, consisting exclusively of ceramic materials, is produced in an economical manner in a firing process in the brick kiln and can be used for brickwork construction.

Its load-bearing areas, which primarily ensure compressive strength, and its insulation areas, which primarily serve as insulation, have a pumice-like structure with a large number of even micropores, are force- and form-fitting in a homogeneous, mainly used as a brickwork.

gel Integrated into a closed outer shell. The different degree of shrinkage of the starting materials for the load-bearing area and the insulation area, which is determined by their properties and also influenced by the different water retention capacity, is specifically used for the form-fitting and force-fitting connection of the areas.

To support an additional insulating effect to a certain extent in the load-bearing areas that are actually used for compressive strength, porosity agents are added to the starting material.

To adjust the compressive strength of the load-bearing area, sand is added to the starting material.

In order to achieve an intensive mixture of the starting material, in particular lowland clay, with the additive that provides additional energy in the firing process, which is important for the uniform high porosity of the insulation area, both are first ground very finely and dried separately and only then mixed and re-moistened to the parameters determined by the material, system and product.

In order to compensate for the inherently higher water absorption and thus shrinkage capacity of the starting materials for the insulation area due to their smaller particles and, in addition, to achieve a shrinkage during drying and firing, albeit very slightly greater in order to avoid shrinkage cracks, a higher volume percentage of additives is added to the starting material for the insulation area in the form of porosity and lean agents than to the starting material for the load-bearing area.

Coal is used as an additive that provides a high level of additional energy during the firing process, creates sintered pore walls and partially sintered bridges from the sinterable components of the starting materials. Furthermore, to control the lower shrinkage, the starting material for the insulation area is given a lower pressing moisture content than the starting material for the load-bearing area. To reduce the surface tension, the starting material can be given

Surfactants are added as wetting agents for the insulation area.

Another advantageous solution is that the raw materials for the insulation and supporting areas, which are prepared in various extrusion presses, are continuously brought together in a clay extrusion in a mouthpiece of a common extrusion tool. This enables very economical production.

In order to support the connection of the insulating area with the load-bearing area, which is partly already caused by a slight shrinkage during the slow drying and subsequent firing process, the joining is carried out in a form-fitting manner in various ways depending on the shape of the composite lightweight brick to be produced.

Using an extrusion press, a blank is first produced from the starting material for the load-bearing area with a recess intended to accommodate the insulation area. For stability reasons, a support web positioned in the recess can be extruded from the starting material of the load-bearing area at the same time. It is intended to insert a pressed part made from the starting material of the insulation area into the recess of the correspondingly positioned blank using the press stamp of a stamping press. This pressed part can have a lower moisture content than the starting material for the insulation area when the blank is produced with the extrusion press. This can also influence the shrinkage behavior to the desired extent.

The additive in the insulation area burns during the firing process of the composite lightweight brick, developing a slightly higher temperature, which is however sufficient to at least partially sinter the pore walls of the pores that are created in place of the particles of the additive, as well as to allow sinter bridges to form in the surrounding shards from the sinterable components of the starting material for the insulation area, but also the directly adjacent load-bearing area.

The sintered pore walls partially touch each other, and in other parts they are connected by the sinter bridges. The insulation area receives a solid pore structure with a pumice-like texture, but with much smaller, more even and more evenly distributed pores.

The invention comprises, according to claim 1, a device for producing the composite lightweight brick. The starting materials prepared with machines known in detail are formed by pressing, brought together and formatted into the blank.

According to an advantageous embodiment, the means for shaping the starting materials consist of extrusion presses, the mouthpieces of which are arranged one inside the other in a common extrusion tool for merging into a clay strand.

Another design of the device also consists of an extrusion press for the starting material of the supporting area as well as a stamping press for introducing the pressed part for the insulation area into the recess of the correspondingly positioned, already formatted molding.

The composite lightweight brick according to claim 7 produced with the device according to the invention is pressure-resistant and highly insulating. It also has a lower weight than a conventional brick. It can be produced economically, largely using machines and systems already available in the brick industry. The load-bearing and insulating areas are positively and force-fitting and are partially firmly connected to one another by sintered bridges. Handling and processing is simple. Losses due to breakage are kept within the usual limits.

The composite lightweight brick is suitable as the sole material for the production of 30 mm masonry, which is used in particular in residential construction. This means that complex shell constructions can be eliminated.

According to a further embodiment of the invention, the insulating area of the composite lightweight brick is on its cold side and the

«■·· .11,

The load-bearing area is arranged on its warm side. This allows the compressive strength and insulating capacity to be used particularly advantageously.

The exclusive use of ceramic materials for the composite lightweight brick also ensures other positive properties such as good water vapor diffusion behavior and very good heat storage capacity.

The invention will be explained in more detail below using exemplary embodiments.

The accompanying drawing shows:

Fig.l: Composite lightweight brick in plan view,

Fig.2: Detail of Fig.l showing the contact surfaces,

Fig.3: another composite lightweight brick in plan view, Fig.4: schematic, enlarged representation of the internal structure of the starting material for the insulation area before the firing process,

Fig.5: Insulation area according to Fig.4, after the firing process,

Fig.6: Insulation area according to Fig.5, with representation of the Sintei— bridges,

Fig.7: partial top view of the device for producing the composite lightweight brick, in a schematic representation,

Fig.8: partial top view of another device, partially rotated, in schematic daisy-chain position,

Fig.9: Forming of the composite brick according to Fig.l, in plan view,

Fig.10: Composite bricks according to Fig.l in masonry bond, in horizontal section,

Fig.11: Composite lightweight brick designed as a brick fascia, in horizontal section,

Fig.12: Brick panel according to Fig.11 used as ceiling walling, in vertical partial section,

Fig.13: Composite lightweight bricks, used as composite insulation

fall,in partial section,

Fig.14: Composite lightweight brick, designed as a thermally insulated U-shell, in sectional view.

In Fig.1 and Fig.3, composite lightweight bricks 10 are shown in block format and made exclusively of ceramic materials. The highly insulating insulation area 7 is enclosed on four sides by the load-bearing area 7. The connection between the insulation area 7 and the load-bearing area 9 at the contact surfaces 8 after the firing process is positive and non-positive due to the slightly greater shrinkage capacity of the starting material 23 for the insulation area 7. The contact surface 8 after the firing process is shown in a schematic, enlarged representation in Fig.2. It is also possible to design the insulation area 7 and the load-bearing area 9 at the contact surfaces 8 with such a profile in the macro area. The connection can be further improved using toothing 40.

In addition, sintered bridges 39 are partially formed at the contact surfaces 8 between the insulating area 7 and the supporting area 9, as shown in Fig. 6.

Brick interlocks 3 serve to better connect the composite lightweight bricks 10 in the masonry. It is advisable to arrange the insulation area 7 near the cold side 2 of the masonry and the load-bearing area 9 on the warm side 1, as shown in Fig. 10. Due to the interlocks 3, the insulation area 7 follows the contour of the enclosing load-bearing area 9. This allows an extension of the heat path between the cold side 2 and the warm side 1. The grip hole 5 primarily serves to better handle the composite lightweight brick 10. To improve the insulating properties of the load-bearing area 9, known means can be used, such as porosity agents (not shown) or high holes 4 surrounded by webs 6, as long as the compressive strength of the composite lightweight brick 10 is not reduced beyond a permissible level. The process for producing a composite lightweight brick 10 with

♦·

The device according to the invention will be explained with reference to Fig. 7, in which a partial plan view of a corresponding device is shown.

Basically, all economically processable clay materials can be used as starting materials 22 for the support area 9. Their grain sizes are approximately 1 mm. The processing (not shown here) is carried out in a known manner and with known systems. Pan mills, rolling mills, precision rolling mills and forced mixers are used in numbers and designs based on the raw material properties and the properties to be achieved in the product. A sump system is also required. Lean agents such as sand or rock powder can be added to the clay materials to adjust the compressive strength. Sawdust and paper pulp, for example, can be added to adjust the bulk density. The starting material 22 prepared in this way is then fed to the extrusion press 19 with the housing 20, the screw 21 and the mouthpiece 18 of an extrusion tool and is further processed by this into the clay extrusion 27.

Separately, the starting material 23 for the insulation area 7 is prepared into fine ceramics. Fat lowland clays are particularly suitable for this. They contain sufficient amounts of sinterable components. The lean materials or other additives that affect the properties can also be added to them. The most important additive 12 has highly porous properties, can be finely ground to a particle size of 0.2 mm like the raw material and provides so much additional energy during the firing process in the brick kiln within the insulation area 7 that the temperature, which is 10 to 30'K higher than the firing temperature of, for example, 900 to 1000°C, locally converts the sinterable components around the pores 13 that are created in place of the burning particles into sintered pore walls 14. Coal has proven to be a suitable additive 12 of this type, which is abundantly available. and is available cheaply.The lowland loams and the coal are ground and dried to about 5% residual moisture.

net and then mixed intensively with each other. To control the, albeit slightly, different shrinkage behavior, the starting material 23 for the insulation area 7 contains a higher percentage volume of additives 12 and admixtures than the starting material 22 for the load-bearing area 9, for example lean materials. If necessary, using wetting agents, for example surfactants, the starting material 23 for the insulation area 7 is remoistened and adjusted to the required moisture content for processing in the extrusion press 24 with the housing 25 and the screw 26.

The starting materials 22;23 are combined via the mouthpiece 18 of the common extrusion tool to form the clay strand 27 with the cross-section corresponding to the top view of the blank 28. The formatting is carried out by means of the separating device 17.

The blank 28 is then slowly dried, whereby, by using the slightly greater shrinkage of the enclosing starting material 22 of the supporting area 9, a certain connection of the insulating area 7 with the supporting area 9 at the contact surfaces 8 is achieved.

If the insulating area 7 is only limited on two sides by the supporting area 9, as shown in Fig. 14, or if both are only adjacent to one another on one side, as shown in Figs. 11 and 12, it is expedient to connect the starting materials 22; 23 in the mouthpiece 18 to the contact surface 8 in a form-fitting manner, for example by means of a dovetail toothing. Such applications are shown in Figs. 11 to 14. These are composite lightweight bricks 10 that deviate from the block-shaped shape of a brick and are designed as special components.

The brick kiln (not shown) is then fed with the blank 28 using the known transport devices. The starting material 23 of the insulation area 7 before the firing process is shown schematically in Fig.4. The additive 12 consisting of coal is added in a proportion of 40 to 60 volumes.

percentages evenly distributed in the clay material 38 of approximately the same particle size. Fig. 5 and Fig. 6 illustrate the state in the insulation area 7 after the firing process. Instead of the burned additives 12, the pores 13 with combustion residues remaining in them in the form of ash 15 are located in the surrounding shard 16. The sintered pore walls partially touch each other, and in other parts they are connected to each other by sinter bridges 39. In the edge area to the support area 9, sinter bridges 39 partially overlap, whereby a strengthening of the already existing positive and non-positive connection between the support area 9 and the insulation area 7 is achieved.

Another embodiment of the device according to the invention for producing the composite lightweight brick 10 is shown in Fig.8. The starting material 22 for the supporting area 9, prepared as already described, is extruded by the extrusion press 19 into a clay strand 29. This corresponds in terms of the Quei— cut the support area 9 and has the recess 30. If necessary, the support web 41 shown in Fig.9 can be extruded into the recess 30 for support. After cutting off using the separating device 17, the molding 31 is formed from it, which is transported on the transport device according to the direction arrow 53 to a tilting table 32. There, positioning takes place according to the direction arrow 34 in a position below the stamping press 35. The starting material 23 for the insulation area 7 is fed as clay material 38 with lower pressing moisture according to the direction arrow 37 to the stamping press 35. As a pressed part 42, it is inserted into the recess 30 of the molding 31 using the pressing stamp 36. At the same time, or even beforehand, the auxiliary web 41 that may have been inserted during the extrusion can also be removed. The blank 28 is thus completed with the insulating area 7 and the load-bearing area 9 and can be slowly dried in the manner already described and fired in the brick kiln to form the composite lightweight brick 10. The variability of the composite lightweight brick 10 is shown in the following.

the applications according to Fig.11 to Fig.14. In the brick panel 46 according to Fig.11 and Fig.12, the load-bearing function of the load-bearing area 9 is of clearly subordinate importance. The ceiling 44, which is usually made of prefabricated parts, rests on the outer masonry 43. On the outside of the masonry 43, the brick panel 46 is arranged with the cold side 2 as a plaster support and at the same time on the warm side 1 as formwork for the concrete 45 cast on site. In the composite insulating lintel according to Fig.13, the load-bearing area 9 also only takes on part of the load-bearing function. It can be combined with the concrete 45 as additional load-bearing elements and thus be used more universally in terms of its area of application.

A comparable application is the thermally insulated U-shell according to Fig. 14. The remaining free space between the insulation area 7 and one part of the load-bearing area 9 within the U-shell can be used, depending on the requirements of the specific application.

List of reference symbols

1 ... Warm side

2 ... cold side

3 ... Brick interlocking

4 ... High hole

5 ... Grip hole

6 ... Bridge

7 ... Insulation area

8 ... contact surface

9 ... Load range

10 ... Composite lightweight bricks

11 ... Sound

12 Additive

13 ... Pores

14 ... sintered pore wall

15 ... Ash

16 ... Shards

17 ... Separator

18 ... mouthpiece

19 ... Extrusion press (for load-bearing area 9)

20 ... Housing (for 19)

21 snail (for 19)

22 ... source material (for 9)

23 ... source material (for 7)

24 ... Extrusion press (for insulation area 7)

25 ... Housing (for 24)

26 snail (for 24)

27 clay strand (for 10)

28 ... blank (for 10)

29 ... Clay string (for 10)

30 ... recess

31 ... molding

32 ... Tilting table

33 ... Direction arrow

34 ... Direction arrow

35 ... Stamp press

36 ... Press stamp

37 ... Direction arrow

38 ... Sound material (for 7)

39 ... sinter bridge

40 ... gearing

41 ... Support bridge

42 ... Pressing

43 ... External masonry

44 ... ceiling

45 ... Concrete

46 ... Brick panel

Claims (16)

Expectations 1. Device for producing composite lightweight bricks of block-shaped or other form for erecting building parts, composed of parts of mainly insulating materials and mainly load-bearing materials, characterized in that - Means for shaping by pressing the starting material (22) for the supporting area (9) and the starting material (23) for the insulation area (7) and - means for bringing together the pressed starting materials (22;23) and - Means for formatting the combined starting materials (22;23) to form the blank (28) of the composite lightweight brick (10) available. 2. Device according to claim 1, characterized in that the means for shaping by pressing for a clay strand of the starting material (22) for the supporting area (9) consist of an extrusion press (19) with a housing (20) and a screw (21) and for a clay strand of the starting material (23) for the insulating area (7) consist of an extrusion press (24) with a housing (25) and a screw (26). 3. Device according to claims 1 and 2, characterized in that the means for bringing together the pressed starting materials (22; 23) in a clay strand (27) for the blank (28) consist of a common mouthpiece (18) of an extrusion tool of the extrusion presses (19; 24). 13 4. Device according to claims 1 to 3, characterized in that the means for formatting the blank (28) from the clay strand (27) consist of a separating device (17). 5. Device according to claim 1, characterized in that the means for shaping by pressing for the clay strand (29) of the starting material (22) for the supporting area (9) consist of the extrusion press (19) with the housing (20) and the screw (21) for extruding the molding (31) with a recess (30) and for a gate material (38) consisting of the starting material (23) for the insulating area (7) consist of a stamping press (35) for pressing a pressed part (42). 6. Device according to claims 1 and 5, characterized in that the means for bringing the molding (31) together with the pressed part (42) and simultaneously formatting it to form the blank (28) by introducing it into the recess (30) consist of a tilting table (32) for positioning the molding (31) and of a press stamp (36) of the stamping press (35). 7. Lightweight composite bricks of block-shaped or other form for constructing building elements, composed of parts of mainly insulating materials and parts of mainly load-bearing materials characterized in that - the composite lightweight brick (10) consisting of at least two clay, loam or similar ceramic starting materials (22; 23) with different properties, produced in a firing process in a brick kiln, - at least one pressure-resistant support area (9) and - at least one insulating insulation region (7) of pumice-like consistency with a plurality of enclosed, largely uniform and evenly distributed pores (13) with at least partially sintered pore walls (14). 8. Composite lightweight brick according to claim 7, characterized in that the insulating area (7) is enclosed on several sides in contact surfaces (8) by the supporting area (9) in a force-fitting manner due to shrinkage. 9. Composite lightweight brick according to claim 7, characterized in that the insulating region (7) rests against the supporting region (9) in a contact surface (8). 10. Composite lightweight brick according to claims 8 or 9, characterized in that on the contact surfaces (8) between the insulating area (7) and the supporting area (9) their connection is designed as an intermeshing, positive toothing (40). 11. Composite lightweight brick according to claims 8 to 10, characterized in that sintered bridges (39) connecting partially on the contact surfaces (8) are formed between the insulating area (7) and the supporting area (9) 12. Composite lightweight brick according to claims 7 to 11, characterized in that the insulating region (7) is arranged on a cold side (2) and the supporting region (9) is arranged on a warm side (1) of the composite lightweight brick (10). 13. Composite lightweight brick according to claim 7, characterized in that the supporting area (9) is designed as a vertically perforated brick with vertical holes (4) and webs (6) arranged between them. 14. Composite lightweight brick according to claim 7, characterized in that the supporting area (9) consists of a porous brick fired from loam or clay, which has been prepared with conventional porosity agents such as polystyrene, sawdust, paper sludge and straw as well as lean agents. 15. Composite lightweight brick according to claim 7, characterized in that the insulating area (7) consists of a highly porous shard (16) of pumice-like consistency with embedded pores (13) and sintered pore walls (14) surrounding them, partially connected to one another by sintering bridges (39), fired from a homogeneously mixed starting material (23) of loam or clay with a high proportion of sinterable minerals and an additive (12) which burns during the firing process of the blank (28) and provides additional energy. 16. Composite lightweight brick according to claim 14, characterized in that the fine ceramic processed starting material (23) of the insulating area (7) has grain sizes of less than or equal to 200 micrometers. 16