EP0436145A2 - Fixing element and method for fixing building parts, in particular door and window frames to wall openings - Google Patents

Abstract

The invention relates to a fixing element in the form of a combination of a three-dimensional coarse-pored foam carrier with an expandable and curable material, which is expanded inside the foam carrier. The fixing element serves to fix building parts, in particular door and window frames to wall openings. <IMAGE>

Description

The invention relates to a mounting element and a method for connecting components, in particular for fastening door frames or window frames to reveal walls.

Door frames and window frames were previously screwed into the corresponding wall opening for attachment to the wall reveal or fastened with the help of claws. More recently, fastening has been carried out by wedging or light screwing, after which the actual fastening is carried out with the aid of assembly foam. This assembly foam is also used for thermal insulation, which is particularly important for window frames. Working with assembly foam requires experience. In the event of improper handling, the assembly foams drift and can go through Deformation or displacement of the frames or frames lead to assembly errors. In addition, most assembly foams contain halogenated hydrocarbons as propellants and are therefore harmful to the environment.

An assembly pack for producing a two-component polyurethane foam is also known. The assembly pack consists of a double bag pack, in which one component contains one component and the second foam component is contained in a second bag arranged within the first bag. After opening the inner bag, the two components are mixed together, after which the two components are discharged between the parts to be connected and react with one another with foaming. Although this foam is free of propellant gas, the foam quality essentially depends on the care taken when mixing the components and is often unsatisfactory.

The invention has for its object to provide a mounting element and an assembly method for connecting components that are easy to handle, are not harmful to the environment and bring good results.

This object is achieved by a mounting element, which is characterized by the combination of a foamable material to form a hard or semi-hard foam in conjunction with a three-dimensional foam carrier with a coarse-pored structure within which the foam can expand. The assembly element can also be referred to as an assembly kit.

The method is characterized in that at least one three-dimensional, coarse-porous support and a foamable material to form a hard or semi-hard foam are placed between the parts to be connected and the parts are joined together by reaction of the foamable material with foaming and curing of the foam.

This combination of foamable material and coarse-porous carrier for the foamable material enables safe and easy work. The coarse-pored carrier forms a container or cage open on all sides for the foamable material. The foam can expand on all sides within this carrier and is guided through the carrier to the parts to be connected or their surfaces without the risk of the foam flowing away before it cures.

The foamable material is preferably free of blowing agents. This means that no blowing agents known as propellants, such as low-boiling hydrocarbons or halogenated hydrocarbons, are added to its manufacture. Such a foamable material is preferred, which develops CO₂ during its reaction, which acts as an internal propellant. Such foamable materials are known. A preferred example is precursors, in particular prepolymers for the production of polyurethane foams. The foamable material is particularly advantageously a prepolymer for the production of a one-component foam and is curable with water.

Blowing agent-free foam precursors do not foam up immediately when released for reaction, as is the case with blowing agent-containing precursors. As a result, the foamable material can spread relatively easily within the porous carrier and completely fills it up during the gradual foaming. The use of a foamable material that is reactive with water enables particularly simple and safe handling. The porous carrier serves as a metering device and as a carrier for the Amount of water and as a mixing device for mixing the water with the foam intermediate. It absorbs the desired amount of water when immersed in water or otherwise wetted with water. The foamable material is preferably foamable and solidifiable at ambient temperature. Such materials are known per se. The foamable and curable material is adjusted or formulated so that it is sticky and acts as a curable adhesive.

The foam carrier is preferably deformable, in particular elastically deformable. As a result, it adapts to predetermined shapes so that you can get by with a few predetermined sizes. The foam carrier preferably has a three-dimensional lattice structure, in particular that of a three-dimensional mesh lattice. It is preferably formed from an open-cell foam, in particular a reticulated foam. With such a foam, the cell walls have burst and shrunk to form webs forming the lattice structure. Open-pore elastic polyurethane foams are particularly preferred.

The average pore size of the pore openings of the porous support is advantageously at least 0.3 mm, preferably 0.5 to 10 mm. The pore size and viscosity of the foam intermediate are expediently coordinated with one another in such a way that the foam intermediate is held in the carrier and the foam formed only emerges from the carrier when it has essentially completely filled the carrier volume. The average pore size of the pore openings is normally at least 1 mm, preferably 2 to 5 mm. The porosity of the carrier can also be expressed by the unit of measure PPI (pores per inch). Particularly suitable average porosities are 7 to 50 PPI, in particular 10 to 30 PPI. The size of the carrier is preferably chosen so that the carrier after the Insert under tension between the parts to be connected. This allows the parts to be connected to be stabilized even before the foam has hardened.

The foamable material can already be contained in the carrier when the porous carrier is introduced between the components to be connected. For this purpose, the carrier can already be impregnated with the foamable material in a predetermined size and, in particular if it is a one-component material that can be foamable and hardened with water, can be packed moisture-tight with exclusion of moisture, for example in an aluminum-clad vacuum packaging. In a preferred embodiment of the invention, the porous carrier has a cavity inside which is free of the pore structure and which serves to hold the foamable material. The foamable material can already be contained in this cavity before the assembly element is used, for example in the form of an easily openable or destructible package which contains a metered amount of foamable material. However, it is also possible and in many cases preferred to design the assembly element as an assembly kit and to introduce, in particular inject, the foamable material into the porous carrier only shortly before the assembly element is used. For this purpose, the carrier can be pocket-shaped. The foamable material can be provided separately from the carrier and pressed into the cavity in a metered amount. It is also possible to form or shape the carrier in cross-section substantially U-shaped or V-shaped, to introduce the foamable material into the cavity formed between the legs of the U or V and then to close the cavity and enclose the cavity insert foamable material between the components to be connected. For this embodiment, carriers are preferred which are designed as strips or strips which can be folded together are that they get a U-shaped or V-shaped cross section. The beams can also have the shape of a U or V profile. Mounting elements in such supports are suitable for connecting along elongated joints or gaps while simultaneously closing and isolating them. This is particularly preferred for window installation.

If the mounting element is prefabricated to such an extent that it already contains the foamable material in a storable form, then when using foamable materials, the combination of support and foamable material is mixed with water, preferably before the mounting element is brought between the parts to be connected. This can be done, for example, by immersing the prefabricated assembly element in water. If a foamable material is brought together with the porous carrier shortly before the assembly element is used, then the porous carrier can be mixed with water before or after the combination with the foamable material. In this case, it is preferred to add water to the support beforehand, because the adjustment of the amount of water and the uniform distribution of the water can be carried out easily before the reaction with the foamable material starts. Water is also preferably added to the porous support before the porous support is inserted between the parts to be connected. The foamable material can in turn be applied or introduced into the porous carrier before the assembly element is introduced between the parts to be connected or afterwards. If the porous carrier has a cavity for receiving the foamable material or at least one insertion channel, then the foamable material can advantageously be introduced into the porous carrier, in particular injected, after it is already between the parts to be connected. However, it is also possible to interpose the porous carrier with the foamable material shortly before its introduction to provide the parts to be connected or, if it is partially inserted. The latter is preferred for supports which are not inserted all at once, but partly in gaps between the parts to be connected, for example in the case of elongated foam supports. Beams with a U-shaped or V-shaped cross-section or beams that are bent to such a cross-section can be pre-fixed by partial insertion into a joint or a gap, after which the inside of the U-shaped or V-shaped cross-section is still existing space is filled with the correspondingly metered amount of foamable material and the carrier is then completely inserted into the joint or the gap while closing the space.

When the foamable material spreads out in the carrier, it meets the water present in the porous carrier and reacts with it with further foaming, the structural elements of the porous carrier, in particular the three-dimensionally oriented connecting webs of the lattice structure, simultaneously performing the function of a static mixer and uniform foaming and Cure the foamable material.

The mounting element according to the invention is preferably inserted into the space between the parts to be connected using an assembly aid. The mounting aid is preferably designed so that the carrier of the mounting element is essentially drawn into the gap provided for insertion or the joint. This prevents compression or jamming of the mounting element during insertion even if the mounting element in its dimension corresponding to the gap width is larger than the gap width and is compressed during insertion. This is preferably achieved in that the engagement area of the mounting aid on the carrier lies essentially on the end face of the carrier lying in the direction of insertion, so that the underlying sections of the carrier are retightened during insertion. This is made possible by the cross-sectionally U or V-shaped configuration of the carrier, the apex of the U or V forming the insertion side of the carrier. The assembly aid preferably has an edge or a web in the direction of insertion, which abuts essentially linearly on the inner apex side of the U or V. The assembly aid preferably extends from this edge or web to the back of the carrier. On this back, it can be grasped by hand or with the aid of a tool. The assembly aid can advantageously be permanently connected to the assembly element. The assembly aid preferably consists of relatively stiff, but elastic-flexible material and at the same time serves as a stiffener for the assembly element.

In particular in the case of prefabricated, essentially pocket-shaped assembly elements, the assembly aid is preferably essentially T-shaped, the transverse web of the T abutting the inner apex line of the carrier. In the line connecting the cavity to the open rear side, the assembly aid can be essentially tubular and form an insertion channel for the foamable material. The opening of this tube can serve as an insertion opening for the tool, which can be designed, for example, as a key.

A curable material is preferably used, which is capable of foaming and curing within a relatively short time. A foamable and curable material with a start time of 45 seconds to 5 minutes, in particular approximately 1.5 minutes, is particularly suitable. The rise time is preferably 2 to 15 minutes, in particular approximately 4 minutes. The curing time is preferably 3 to 25 minutes, in particular approximately 8 minutes.

The amount of curable material in relation to the volume of the foam carrier can vary within wide limits and depends on the foamability of the foamable material. The volume is usually in a ratio of 10: 1 to 30: 1, especially in the case of a polyurethane prepolymer.

The lattice structure of the foam carrier also serves as reinforcement for the finished foam. As mentioned above, reticulated foams are preferred for the lattice structure. However, other materials such as three-dimensional wire mesh or wire mesh made of metal or plastic wire and similar three-dimensional structures with a large pore volume can also be used.

The size of the carrier depends on the intended use. Usually the size of the carrier is 5 x 5 cm to 20 x 20 cm, preferably 10 x 10 cm to 15 x 15 cm, including the intermediate rectangular sizes. The thickness of the mounting element or the carrier can vary between a few millimeters and a few centimeters, and in particular lie between approximately 5 mm and 10 cm, preferably between 1 cm and 5 cm. The same applies to supports made of lattice structures in strip form, the strip length being adapted to the joint length. Since the carriers are preferably formed in two layers by folding them once, the size of the starting material for the carrier is accordingly half as thick in thickness and twice as large in depth as in the finished carrier.

Fig. 1

eine bevorzugte Ausführungsform für die Montage von Türzargen im Schnitt entlang der Linie I-I nach Fig. 2;

Fig. 2

die Ausführungsform nach Fig. 1 im Schnitt entlang der Linie II-II nach Fig. 1, jedoch mit abgenommenem Montagewerkzeug;

Fig. 3

die Ausführungsform nach Fig. 2 in Rückansicht;

Fig. 4

eine bevorzugte Ausführungsform für die Fenstermontage;

Fig. 5

eine Montagehilfe für die Ausführungsform nach Fig. 4.

Further features and details of the invention emerge from the following description of preferred embodiments in conjunction with the drawing and the subclaims. The individual features can be implemented individually or in combination in the individual embodiments. The drawing shows:

Fig. 1

a preferred embodiment for the assembly of door frames in section along the line II of FIG. 2;

Fig. 2

the embodiment of Figure 1 in section along the line II-II of Figure 1, but with the assembly tool removed.

Fig. 3

the embodiment of Figure 2 in rear view.

Fig. 4

a preferred embodiment for window mounting;

Fig. 5

an assembly aid for the embodiment of FIG. 4th

In the assembly element or assembly kit 1 shown in FIGS. 1 to 3, a reticulated polyurethane foam of size 15 x 30 cm and a thickness of 1 cm along its short center line is turned over once, so that there is a double-layer, essentially square foam with the edge length of approx. 15 cm, which has a thickness of approx. 2 cm. This foam forms the carrier 2 of the mounting element. On its front side 3, the carrier 2 is rounded off by the folding, as a result of which an insertion bevel is formed for easier insertion of the assembly package into gaps between the door frame and the reveal. The foam is soft and elastic and, due to the reticulation, has an open-pore lattice structure with an average pore size of 2 mm. This lattice structure is shown in more detail at 5. Along the longitudinal edges 5, the two layers of foam 2 are connected to one another by gluing, so that there is a pocket-shaped configuration of the carrier results, which is only open at the rear 6. Regardless of this, however, the carrier has its open pores 7 on all sides.

An assembly aid 8 is assigned to the carrier 2 and is formed in two parts in the embodiment shown. A part 9 of the assembly aid 8 is located inside the pocket-shaped carrier 2, a second part 10 protrudes from the rear 6 of the carrier and serves as a detachable handle. For mutual fastening, the part 9 located in the carrier 2 has a tubular extension 11 projecting approximately from the center of the carrier to the rear side 6, into which the T-shaped part 10 can be inserted by means of its longitudinal web up to a shoulder-shaped extension. The part 9 of the assembly aid 8 located within the carrier 2 is also essentially T-shaped, the two parts 9 and 10 together resulting in a double T. The crosspiece 12 of the part 9 lies against the inner envelope edge 13 in the region of the front 3 of the carrier 2 and extends essentially over the entire width of the carrier 2. Apart from the tubular extension 11, the mounting aid 8 is essentially flat, around which To impair the compressibility of the mounting element as little as possible. Circumferential reinforcing edges 14 serve to stiffen the assembly aid 8. The part 9 of the assembly aid 8 located in the carrier 2 also has openings 15 which enable penetration with foam.

For the assembly of a door frame on a wall reveal, the assembly pack can be gripped on the handle 10 of the assembly aid 8, immersed in water and pressed in between the frame and the reveal in the wet state, with the front side 3 ahead. In this case, only the area between the inner edge 13 and the front side 3 of the carrier 2 is compressed in the longitudinal direction, with the remaining parts of the carrier being more likely to be inserted during simultaneous compression be slightly stretched in the direction of insertion, which makes insertion easier. The mounting element then sits in the gap in the wet state under lateral pretension, the rear side 6 being flush with the edges of the gap. After removing the handle 10 of the assembly aid 8, the pipe opening 16 of the pipe socket 11 is opened in the area of the rear 6. The mounting element is assigned a foamable material, not shown in the drawing, in a metered or metered amount. A metered amount of the material, in particular a blowing agent-free polyurethane prepolymer 28 with excess isocyanate groups, is now injected through the pipe opening 16 and initially spreads out in the central region of the pocket-shaped carrier 2, as is shown schematically in FIG. 2. Upon contact with water, the prepolymer begins to foam with CO₂ development and experiences an increase in volume of about 20 times. The foam formed first spreads out within the reticulated foam serving as a carrier, and when it hits the webs of the lattice structure wetted with water, a metered and gradually increasing contact with the water takes place and leads to increased foaming. At the same time, excess water is displaced from the pores. The newly formed foam fills the carrier substantially completely and then emerges from its open-pored outer surfaces and comes into surface contact with the components to be connected, with which it firmly bonds due to its adhesive properties. Excess foam can escape at the side edges without leading to a pressure build-up in the area of the assembly pack. As a result of the rapid reaction of the prepolymer with the water, which is preferably used in excess, the foaming reaction of the prepolymer comes to a standstill. This also avoids pressing the foam. Instead of an injection of prepolymer 28, the foamable material can already be contained in an easily destructible package at 28 in the carrier 2.

The prepolymer is preferably formulated to have a start time for the reaction of about 1.5 minutes, a rise time for the expansion of the foam of about 4 minutes and a curing time for the foam of about 8 minutes. The prepolymer can contain conventional foam stabilizers, such as silicone polymers, flame retardants, such as trichloroethylphosphate, catalysts, such as tertiary amines and tixotropic agents.

In the embodiments of the invention shown in FIGS. 4 and 5, a wall reveal 21 and a window frame 22 are shown schematically, between which there is a gap 23. A foam strip 24 is provided here as the carrier of the assembly element 20 according to the invention, which can also be referred to as an assembly kit, the thickness of which is somewhat greater than half the gap width and the width of which is approximately twice the gap depth. The length of the strip 24 corresponds approximately to the gap length. The foam strip 24 in turn preferably consists of a reticulated plastic foam. However, it can also consist of another compressible lattice structure which has an open pore size of about 1 to 4 mm pore size which is sufficient for the penetration with foam.

As shown in Fig. 4, the foam strip 24 is folded over along its longitudinal center line, so that there is a substantially U-shaped to V-shaped cross section. In this state, the foam strip 24 is partially pushed so far into the gap 23 that a cavity 27 remains between the legs 25 and 26 of the U-profile for receiving foam prepolymer 28. Before insertion, the foam 24 is immersed in water wetted with a sufficient amount of water for the reaction with the prepolymer. The prepolymer 28 can preferably be introduced continuously into the cavity 27 with the aid of a spray gun, not shown, into which a cartridge 29 with the spray nozzle 30 containing the prepolymer is inserted.

The foam strip loaded with the prepolymer inside can then be completely pressed into the joint 23 with the aid of a flat assembly aid 31. The assembly aid 31, as shown in FIG. 5, is again made up of two parts, but it is constructed symmetrically and has two identical interlocking halves. Whenever the foam starts to foam on the assembly aid, the soiled half can be left inside the foam strip and remains there. The assembly aid is then supplemented by attaching a new clean half, which is used as a handle. In this way you can work quickly and cleanly. The reactivity of the prepolymer can be adjusted in a similar manner as in the previous embodiment. However, if very long foam strips 24 are used for long joints 23, it is preferred to set the prepolymer somewhat less reactive.

Claims (33)

Mounting element for connecting components, in particular for fastening door frames or window frames to a wall reveal, characterized by the combination of a foamable material (28) to form a hard foam with a three-dimensional foam carrier (2; 24) with a coarse-pored structure within which the foam is located is able to expand. Mounting element according to claim 1, characterized in that the foamable material (28) is a prepolymer, in particular one for producing a polyurethane foam. Mounting element according to claim 1 or 2, characterized in that the foamable material (28) is a prepolymer for a one-component foam and can be hardened with water. Mounting element according to one of the preceding claims, characterized in that the foamable material (28) is free of blowing agents. Mounting element according to one of the preceding claims, characterized in that the carrier (2; 24) is deformable, in particular elastically deformable. Mounting element according to one of the preceding claims, characterized in that the carrier (2; 24) consists of a three-dimensional grid, in particular a three-dimensional mesh grid. Mounting element according to one of the preceding claims, characterized in that the carrier (2; 24) is an open-pore foam, in particular a reticulated foam. Mounting element according to one of the preceding claims, characterized in that the average pore size of the pore openings of the carrier (2; 24) is at least 0.3 mm, preferably 0.5 to 10 mm. Mounting element according to claim 8, characterized in that the average pore size is at least 1 mm, preferably 2 to 5 mm. Mounting element according to one of the preceding claims, characterized in that the porosity of the carrier (2; 24) is 7 to 50 PPI, in particular 10 to 30 PPI. Mounting element according to one of the preceding claims, characterized in that the carrier (2) has two substantially parallel side surfaces, in particular is essentially cuboid. Mounting element according to one of the preceding claims, characterized in that the cross-section of the support (2; 24) is essentially U-shaped, in particular is essentially pocket-shaped. Assembly element according to one of the preceding claims, characterized in that an assembly aid (8, 31) is assigned to the carrier (2; 24), which is preferably essentially rigid. Mounting element according to claim 13, characterized in that the mounting aid is essentially flat and designed for arrangement within the carrier (2; 24). Mounting element according to one of the preceding claims, characterized in that the carrier (2; 24), in particular on its rear side (6), has an opening (16; 27) for receiving the foamable material (28). Mounting element according to one of the preceding claims, characterized in that the mounting aid acts on the carrier (2; 24) essentially along its entire front side (3, 13). Mounting element according to one of the preceding claims, characterized in that the mounting aid (8, 31) protrudes on the rear of the carrier (2; 24) and the projecting part (10) preferably from a part (within the carrier (2; 24)) 9) is removable. Mounting element according to one of claims 13 to 17, characterized in that the mounting aid (8) has a pipe socket (11) for introducing the prepolymer (28), which preferably at the same time for mutually fastening the two parts (9 and 10) of the mounting aid (8 ) serves. Mounting element according to one of the preceding claims, characterized in that the carrier (24) is formed by a flexible strip made of the coarse-porous material which, before being introduced into a gap (23) between the parts (21, 22) to be connected, in cross section U - or V-shaped can be turned over. Method for connecting components, in particular for fastening door frames or window frames to wall reveals, preferably using the mounting element according to one of the preceding claims, characterized in that at least one three-dimensional, coarse-pored carrier and a material which can be hardened to form a hard foam are connected between the two Parts are brought and the parts are connected by reaction of the material with foaming and curing of the foam. A method according to claim 20, characterized in that the curable material is foamed within the carrier and for this purpose, preferably after the at least partial introduction of the carrier between the parts to be connected, is metered into the carrier. Process according to one of Claims 20 and 21, characterized in that a material which can be foamable and hardened is used and the carrier is preferably moistened by immersion in water in order to effect the foaming and hardening of the foamable material. Method according to one of claims 20 to 22, characterized in that a prepolymer is used as the foamable and hardenable material for the production of a polyurethane foam. Method according to one of claims 20 to 23, characterized in that the carrier is introduced, in particular essentially pulled in, between the parts to be fastened by means of an assembly aid. Method according to one of claims 20 to 24, characterized in that a carrier is used, the thickness of which is greater than the gap width between the components to be connected, and that the carrier is compressed, in particular elastically compressed, when it is introduced into the gap. Method according to one of claims 20 to 25, characterized in that at least part of the assembly aid is left in the assembly element during the foaming and curing of the foamable material. Method according to one of claims 20 to 26, characterized in that the amount of the foamable material is matched to the volume of the porous carrier such that the volume of the foam formed from the foamable and curable material is greater than the volume of the carrier. Use of a three-dimensional grid as a support for foaming plastic foams. Use of a three-dimensional grid according to claim 28 in combination with a foamable material to form hard or semi-rigid foam for fastening components. Use according to claim 28 or 29, characterized in that the foamable material is arranged within the porous carrier before foaming. Three-dimensional grid for use according to one of claims 28 to 30. Use of a water-foamable and curable propellant-free prepolymer, in particular polyurethane prepolymer, for connecting components to fill in the cavity, in particular according to one of Claims 28 to 30. Water-foamable and curable prepolymer for use according to claim 32.

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