DE29700606U1 - Component made of mainly foamed base material - Google Patents

Description

GERMAN PATENT OFFICE 10 January 1997

80331 Munich

Paul Lingen

Applicant No.: 49 46 871
Grefrather Strasse 42
47669 Wachtendonk / Wankum

Utility model application

Construction element made mainly of foamed base material

Plate-shaped construction element or molded part for building construction made of foamed plastic or glass, which is used as a self-supporting or non-self-supporting insulation, wall, floor, ceiling or facade element for the construction of buildings and, depending on the construction task, is equipped with a layer of another material on at least one side of the base material.

Insulating panels made of glass or mineral fibre (e.g. G+H ISOVER, ROCKWOOL ₁ etc.) have been known in the construction industry for many years and have been used for insulating walls and ceilings inside and outside buildings as well as in many other areas of application. The disadvantage of these panels, which usually provide very good insulation even in thin panels, is the very low strength of the

Plate that does not allow any mechanical stress, so that this type of insulation basically requires a supporting structure.

To counteract this disadvantage, many other insulating materials with statically definable strength have come onto the market in recent decades.

These include, for example, insulating panels made of foamed glass (e.g. FOAMGLAS), in which the liquid glass is foamed in such a way that a homogeneous panel is formed from largely uniformly sized bubbles, the shell of which is formed from the solidifying glass.

Aerated concrete slabs and molded parts (e.g. HEBEL, YTONG, etc.) are constructed in a similar way, although they also have increased strength values.

Furthermore, insulating building boards made of chipped wood are known (e.g. HERAKLIT) ₁ which are processed with cement to form a board interspersed with many insulating air spaces.

In addition, polyurethane panels made in sandwich construction (e.g. HOESCH) have recently come onto the market to an increasing extent, with the front and back (sandwich sides) made of smooth or shaped sheets or foils, so that these panels combine excellent static properties with good insulation values and quick assembly.

The serious disadvantages of these panels are the limited application possibilities (almost exclusively used as single-layer walls and ceilings in industrial and commercial buildings), the high proportion of atmospherically harmful gases that are produced during the foaming process and the raw materials mainly used: oil, natural gas and coal.

The invention is based on the object of creating building elements as molded parts or in particular as building boards, which are formed from a foamed insulation or insulating layer and which, depending on the inventive design, contain material or materials ^ for solidifying the insulating layer and, in further designs of the invention, at least one adjacent layer made of another material or material mix is provided on one or more sides or in multiple layers.

These building elements are intended to be used to manufacture insulating components, in particular, in addition to simple insulating panels, walls, floors, ceilings and, if necessary, molded parts made in specially made molds, which, after assembly, only need to be provided with an external plaster or paint or internal plaster, paint, cladding, wallpaper or other material in order to then create a finished wall or ceiling.

The object of the invention is achieved, for example, in such a way that in the simplest embodiment of the components, a foamed insulating component or insulating plate is produced in one piece or in one layer, mainly either from plastic or, in an inventive embodiment, from cement or gypsum foam. But all other base materials that can be foamed and hardened, such as aerated concrete, glass and others, can of course also be used.

During the production of the component, it is possible to adapt the foam or the element to its task via the bubble size of the foam and/or the thickness of the bubble skin. If good insulation is important, the bubble diameters are relatively small (air movement in the bubble should be prevented) and the bubble skin should be as thin as possible. For base materials subject to static stress, large bubbles with a thick bubble skin can better meet this requirement.

The thickness of the bubble skin can be influenced by the viscosity of the base material that has not yet been foamed and/or additives that promote cross-linking.

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The bubble diameter is to be determined via the degassing components during the chemical reaction or during mechanical foaming depending on the base material viscosity or cross-linking ability via the air or gas mixture that is forced in at the specified ratio (solids to gases per volume fraction).

A feature of the invention is that the foamed base material enables the formation of a very stable insulating layer, which cannot be achieved in any way with mineral wool. In addition, this insulating layer can be provided with cover layers made of the same non-foamed or only partially foamed base material during production, so that, for example, when using gypsum, a construction element can be manufactured in which the inner insulating layer is provided in the foamed state and the gypsum is provided as the outer layer of the element in the non-foamed original state.

In order to give the base material or the entire plate or molded part made of a material greater strength, a material consisting of tear-resistant fibers can be mixed in, for example, in an embodiment according to the invention, so that an increased bending and tear resistance of the component is achieved through the large number of fibers distributed as evenly as possible in the base material and/or its foam, whereby these strengths can be directly influenced to a certain extent through the type and/or amount of fiber.

If this tear or breaking strength is only required in the outer areas of the structural element, at least one layer made of fibers or their mats or mesh, or wire or steel mesh can be used in the outer area to increase the strength, as is also used in screed or reinforced concrete construction, for example.

In addition, this strength-enhancing layer can also be guided in, for example, a wave or trapezoid shape from the top to the bottom through the foamed base material in order to increase the strength of the component in another way.

In this case, the internal material reinforcement made of fibers may be dispensed with, provided that the foamed base material itself is able to absorb the expected transverse forces.

Of course, depending on the application, all possible combinations of the base material with one or more of the strength-enhancing designs are possible, so that, for example, a particularly stable element made of fiber-reinforced foam can be equipped with embedded steel mesh and steel mats on the top and bottom.

In addition to the aforementioned design options that reinforce the foamed base material, the component is open to all possibilities in its further layer structure.

For example, one or more sides of the base material can be provided with expanded metal, perforated sheets, granulate, sand or chippings as a plaster carrier in order to provide a well-adhering substrate for a subsequent plaster layer.

In the same design, these sides of the base material can, for example, be equipped with a sheet metal or plaster or cement layer directly from the manufacturer's factory. This plaster or cement layer can also be reinforced in the aforementioned manner using fibers, mats and/or steel inserts.

It is even conceivable that brick slips, clinker or other masonry is already attached to the building element on at least one side at the factory, although an intermediate layer of plaster or cement, or another stable intermediate layer, is recommended for heavy masonry.

In order to increase the mass of the base material, for example for acoustic reasons, mineral additives can be added to the lighter foaming agents such as polyurethane in the form of powder and/or granules.

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If gypsum is used primarily to form the building elements, good moisture balance from the inside to the outside is guaranteed. This is not the case with PUR foams (plastics), which are also widely used in the construction sector, so walls should either only be built on the outside or in a double-shell design to ensure that the moisture is transported away.

This double-shell or multi-shell construction can be implemented directly on the building or, in accordance with the invention, integrated into the building element. Either the same or different base materials can be integrated into a building element in several layers, whereby free spaces can be provided between the individual layers for building physics requirements.

In order to bridge the gaps, the material-strengthening wire or steel mesh can be led from a foamed base layer to the adjacent spaced base layer or another layer such as a plaster or cement layer or masonry layer.

To round off the design options, the installation of standardized window frames and casings is also planned for the production process. The integration of empty pipes for electrical, heating and plumbing installations is also of course provided.

In order to ensure a precise connection between standardized components, at least two-sided tongue and groove connections have proven to be effective. However, all other connection systems such as plugging and screwing, as well as gluing or cementing, can also be used freely depending on the application.

If one takes advantage of the aforementioned possibilities for component production, components can be manufactured that essentially consist of a foamed insulating base material, which can either be used as insulating material in this simple form or in ever more advanced designs, e.g.

reinforced load-bearing insulation panels for interior construction to ready-to-build house walls, ceilings and floors for prefabricated buildings.

As can already be seen from the previous, the foaming of the base material plays an important role in the implementation of this invention.

The foaming of plastics (especially polyurethane) has long been known in the construction sector.

However, particularly when combining the granulate, sand or grit with liquid, chemically expanding (foaming) base materials, it is important to ensure that the still liquid base material is not sprayed onto the granulate, sand or grit in one layer as is usually the case, as the foam that forms will then absorb the grains of the plaster base and distribute them within the foam, but rather that the still liquid base material is applied in an inventive design in a first thin layer that only binds the granulate, sand or grit and only then is the second, more foaming layer applied.

This problem can also be addressed by injecting a non-expanding layer of adhesive or pre-foamed base material onto or into the grains of the plaster base or by pressing it in as foam.

This ensures that the plaster base layer partly protrudes from the building element to provide support for the plaster and is also integrated into the building element in a form-fitting and force-fitting manner.

Another way of producing foam is mechanical foaming, in which not only plastics but also mineral, liquid mixtures can be foamed by mixing compressed air or gas mixtures into the base material in addition to the base material and then foaming it using one of several process variants and then feeding it into processing.

In particular, during mechanical foaming, it is possible to significantly influence the physical values of the finished component by individually selecting the bubble diameter and/or the bubble skin thickness by changing the proportions in the base material (solids content to gas content per volume fraction).

To make this possible, the addition of wetting or binding agents may be unavoidable. This serves to enable the desired type of foam, in particular a large bubble diameter, which must ensure the desired component-specific strength values beyond the drying phase.

This mixing with binding agents can be carried to such an extent that the base material consists primarily of gypsum or cement in powder and/or granulate form with a high plastic content (e.g. PUR).

Several embodiments of the invention are shown in the drawings. They show

Fig. 1 is a perspective view of a component consisting of foamed, fiber-reinforced base material,

Fig. 2 is a perspective view of a component consisting of foamed base material with layers on both sides of non-foamed base material with integrated fiber composite,

Fig. 3 a perspective view of a component consisting of foamed, fiber-reinforced base material with integrated steel wire mats and layers of glued fiber composite mats on both sides,

Fig. 4 is a perspective view of a component consisting of two different foamed, fiber-reinforced base materials with integrated steel wire mats and layers on both sides,

Fig. 5 shows a cross-section through the manufacturing process of the component during the three-layer application of the still liquid, non-expanding base material according to Figure 2.

Fig. 6 a cross-section through the manufacturing process of the component during the two-layer application of the still liquid base material undergoing expansion onto a granulate layer.

Fig. 7 shows a cross-section through the manufacturing process of the component during the two-layer application of the still liquid base material, which only expands in one layer, onto a layer of sand.

The component (10) shown in Figure 1 consists of foamed power plant gypsum, into which highly tear-resistant carbon fibers (11) with a form-fitting shape for bonding to the gypsum were mixed before foaming. After drying, a tongue and groove system (13) was milled into the two end faces (12). The two long sides (14) were already provided with the grooves during the continuous manufacturing process, which runs on a conveyor belt.

The component (15) shown in Figure 2 is the same in material and dimensions as the component (10) shown in Figure 1. In contrast, this element was not provided with carbon fibers in the foamed interior (16). Instead, carbon fibers (11) were mixed into the non-foamed visible sides (17+18) to create a rigid sandwich element before processing.

The component (19) from Figure 3 is also the same in material and dimensions as the component (10) shown in Figure 1. As this component (19) is designed as an insulating intermediate ceiling with a load-bearing function for ventilation systems, steel wire mats (20) have been embedded in the fiber-reinforced base material (21) on both sides. In addition, a glass silk fabric (22) was glued onto one side, which, after painting, will form the visible side of the subsequent ceiling element.

Figure 4 shows a section of a wall element (23) for prefabricated house construction. The wall structure from the inside to the outside corresponds to the usual construction method. For hydroscopic reasons, a smooth gypsum plaster layer (24) has been applied to the inside, which can be wallpapered during production, to which the insulating wall made of a foamed gypsum layer (25) (with a strength similar to aerated concrete) is attached on the outside. After a gap forming a ventilation layer (26), an additional insulating PUR rigid foam layer (27) follows as an outer layer for weathering reasons, into which a layer of chippings is embedded on the very outside as a carrier layer (28) for plaster, brick slips or similar. As an additional strength-enhancing

An important accessory is a hot-dip galvanized steel wire skeleton (29) embedded in the entire construction, the mats (30) of which are welded to many steel wires (31) running through the individual component layers (24,25,26,27,28) to support transverse forces.

Figure 5 shows the production of a three-layer plate (32) according to Figure 2, where the three flat nozzles (33, 34, 35) that apply the material extend over the entire width of the plate (32).

Figure 6 shows the production of a PUR rigid foam panel (36) for subsequent facade insulation, with two nozzle rods (37,38) oscillating over the entire width of the element, of which the first nozzle rod (37) only foams the granulate layer (39) and the second nozzle rod (38) applies a second PUR mass to the already expanded first layer, which forms the core of the panel (36) after expansion.

Figure 7 shows a construction element (40) as described in Figure 6. However, since only a thin layer of sand (41) is to be applied on one side, in this case the first layer (42) of the two-layer element is designed as a non-expansive adhesive layer (42).

List of reference symbols

10 Construction element 27 PUR rigid foam layer 11 Carbon fibers 28 Carrier layer 12 Front sides 29 Steel wire skeleton 13 Tongue and groove system 30 Steel wire mats 14 Long sides 31 Steel wires 15 Component 32 plate 16 Inside 33 Flat nozzle 17 Visible side 34 Flat nozzle 18 Visible side 35 Flat nozzle 19 Component 36 PUR rigid foam board 20 Steel wire mats 37 Nozzle holder 21 Base material 38 Nozzle holder 22 Glass silk fabric 39 Granulate layer 23 Wall element 40 Construction element 24 Gypsum plaster layer 41 Sand layer 25 Gypsum layer 42 Adhesive layer 26 Ventilation layer

Claims (13)

ient claims 1. Plate-shaped construction element (10) or molded part for building construction made of foamed plastic (36) or glass, which is used as a self-supporting or non-self-supporting insulating, wall, floor, ceiling or facade element (10) for the manufacture of buildings and, depending on the construction task, is provided with a layer of another material (39,41) on at least one side of the base material (25,27,36), characterized in that foamed gypsum (25) or foamed cement is used as the base material (21). 2. Plate-shaped component (10) or molded part according to claim 1, characterized in that a strengthening of the base material (21) is achieved by incorporating strength-increasing materials (11) in the form of tear-resistant fibers in the base material. 3. Plate-shaped component (10) or molded part according to claim 1 and 2, characterized in that a consolidation of the base material (21) is formed by at least one layer of sheet metal or of steel wires (20, 31) or its mesh (29, 30) or fibers (11) (made of steel, plastic, or other) or its fabric (22). 4. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that by varying the bubble diameter and/or the bubble skin thickness of the foamed base material (21), the component (10, 15, 19, 23, 25, 27, 32, 36, 40) can be adapted to different requirements. 5. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that additives are added to the base material (21) which influence the foam formation during production and foam curing in order to achieve the service strength. 6. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that the foaming of the base material (21, 25, 27, 36) takes place chemically and/or mechanically. 7. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that at least one component layer (21, 25, 27, 36) is made of foamed base material (21, 25, 27, 36). 8. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that at least one component layer (11, 20, 22, 24, 26, 28, 29, 30, 31, 41, 42) is made of non-foamed base material or any other material. 9. Plate-shaped structural element (10) or molded part according to one of the preceding claims, characterized in that at least one visible side (17, 18, 24, 28, 39, 41) is provided with a layer of fabric, sand, chippings, granulate, plaster, clinker or the like. 10. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that the base material (21, 25, 27, 36) is increased in density by powder and/or granulate additives. 11. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that at least one of the component layers is an air layer (26). 12. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that Components required in the future, such as frames, casings and cables, are to be used during production. 13. Plate-shaped component (10) or molded part according to one of the preceding claims, characterized in that the component is equipped with connection systems for the connection together, such as an at least two-sided tongue and groove system (13).