EP1584767A1 - Plate-shaped buidling element and method of manufacturing - Google Patents

Abstract

Construction element, especially a plate-shaped construction element, comprises at least two layers (A, B) containing cellulose elements or cellulose-containing elements such as wood chips, cement as a binding agent, and optionally aggregates. Each layer consists over the entire layer thickness of a mixture of cellulose elements or cellulose-containing elements of all fractions of the same sieve line. The cement is uniformly distributed through the layer thickness (S). Adjacent layers are joined together by their boundary surfaces (FA, FB) and have different crude densities depending on the cement content or the degree of packing. An independent claim is also included for the production of a construction element, especially a plate-shaped construction element.

Description

The invention first relates to a component according to the preamble of claim 1 Such a device is described in DE 25 48 210 B2 described.

For the preparation of the known device one uses one Fiber or chip mixture. This will after cutting in at least two fractions, namely in fine material with a chip size of 2-8 mm and normal with a chip size of 8-20 mm - of which at least 80% larger than 12 mm - split and each of the fractions by itself with binder cement mixed. Here, the fines fraction is added much more cement than the normal fraction. The two fractions mixed with the binder cement are sprinkled by air classification on a base, with the Sprinkle at least three gradually merging, in relation to Fiber or chips to cement ratio different layers are generated. According to a preferred embodiment of DE 25 48 210 B2, the main fraction (64%) consists mainly of one Spangemisch of 5-12 mm in length, which is a reinforcement of the plate-like component and, associated with it, also the corresponding strengths should ensure. The fine fraction (0-5 mm) of about 14% of the total weight the chips are placed in the outer layers. Here is the structure made the known plate-like component so that a gradual Transition from the outer uniform fine layers to the inner ones Coarse layer occurs.

Structure and manufacture of the plate-like component accordingly DE 25 48 210 B2 are perceived as very complicated and costly.

From DE 34 06 895 A1 discloses a method for producing cement-bound Wood fiber molded body known in which to mix with a content of Portland cement, water and wood shavings or wood wool, and optionally with customary additives deformed and under pressure and optionally cured with heating to dimensional stability. Of this known document, it is also known, amorphous silica for mineralization the wood components (beech chips) to use.

From DE 198 26 109 C1, a composite plate is known, which consists of at least two layers, with a layer of concrete and a further consists of an insulating material, which consists of a mixture of Water mixed pulp and cement is formed. Thus, the known composite panel on an entirely made of concrete outer wall, which is a supporting element. Inside is the plate with the pulp and cement prepared insulation board provided. The composite plate according to DE 198 26 190 C1 is considered disadvantageous because of the supporting function the composite panel securing concrete area virtually no contribution to thermal insulation the composite plate makes.

Finally, in general, plate-like components are made of monostructured Aerated concrete known. Such an aerated concrete plate meets both a thermal insulation function as well as a support function. However, that will be both the thermal insulation function on the one hand and the support function on the other each not perceived as optimal.

Based on the device described above accordingly DE 25 48 210 B2, the invention is based on the object, a universal To provide applicable device, which is relatively easy to manufacture and which as integrated component different functions, in particular the support function on the one hand and the thermal insulation function on the other hand, optimally fulfilled.

According to the invention, this object is achieved together with the Features of the preamble of claim 1 with its characterizing Characteristics solved in that each layer substantially over the entire layer thickness of a mixture of cellulose elements or cellulosic elements of all fractions of the same sieve line is that the cement is evenly distributed over the layer thickness that is the other facing adjacent layers with their interfaces firmly together are connected and that adjacent layers depending on Cement content and / or different depending on the degree of compaction Have crude densities.

In contrast to the device according to DE 25 48 210 B2 an essential advantage of the device according to the invention, that the particle size distribution of the cellulose elements or the cellulosic Elements beyond the thickness of a layer are not complicated Way individually along a gradient, but that each layer essentially over the entire layer thickness away from cellulosic elements or cellulosic elements of all fractions of the same grading curve. This feature of the invention is essential for easy manufacturing handling and for the highest level of manufacturing identity as a prerequisite for consistent Material properties.

In contrast to the device according to DE 25 48 218 B2 is the Cement not inhomogeneous, but rather homogeneous over the entire Layer thickness distributed. This feature of the invention also serves for simple production handling, a maximum of manufacturing identity and as a prerequisite for uniform material characteristics.

Another feature of the invention is that the facing each other adjacent layers with their interfaces firmly connected are. Here, a gap-free homogeneous compound is preferred, which For example, by bonding the facing surfaces adjacent layers can take place. Through this solid connection each other facing adjacent layers by means of their interfaces arises integrated component.

It is particularly important that adjacent layers in Dependence on cement content and / or depending on the degree of compaction have different densities.

Within the scope of that feature of the invention There is a particularly advantageous combination in that both together adjacent layers of the same mixture of cellulosic elements and / or cellulosic elements of all fractions of the same Siebkennlinie However, the one layer meanwhile a relatively low cement content and the other layer includes a relatively large proportion of cement.

Such a composite component has, on the one hand due to the Layer with the relatively low cement content, accompanied by a lower Density, a very good thermal insulation value and on the other hand because of the layer with the relatively large proportion of cement, accompanying with a greater bulk density, over a very good support function.

An equally advantageous, good thermal insulation function and good support function Combined component according to the invention is then achieved if you mix for both layers with the same recipe and with Cellulosic elements or cellulosic elements of the same grading curve used and one of the two layers not or only slightly compacted. On this way has the latter layer with the lower bulk density very good thermal insulation properties, while the neighboring others Layer is compressed to a greater bulk density, combined with a good Carrying function, to achieve.

As already mentioned, both adjacent layers of the invention Component with their interfaces firmly connected be. In a particular embodiment of the invention, this happens in the Way that the adjacent layers in the area of their facing each other Penetrate interfaces, the penetration area a represents a cohesive and form-fitting composite mixing zone.

In practice, this is done so that the first layer with the example greater proportion of cement first poured into a mold and a certain setting time, without a complete hardening, waited and then the lower cement content having second yet fairly flowable layer is applied. In this way results in the Interfaces of the two layers by an interlocking of the cellulose elements or the cellulosic elements both a positive bond as well as by the inflow of the second layer into the cavities of first layer a cohesive composite.

As already mentioned, an essential feature of the invention is that the layer with the respective lower bulk density, the thermal insulation function and the layer with the respective greater bulk density, the supporting function of the device Fulfills.

In addition, the bulk density is due to variation of cellulosic elements or the cellulosic elements in addition to determine or vary. This is done according to the invention in that the bulk density additionally by the density of the cellulosic elements or the cellulosic elements determinable is. Thus, hardwoods, especially hard tropical woods, have a larger one Density on as softwoods.

According to the invention, the bulk density for the modification of particular building physics Properties, e.g. for changing sound transmission properties, additionally be varied by making the mixture independent from the cement portion, mineral admixtures, e.g. a specific one particularly heavy admixture in the form of barium sulfate, admits.

As already mentioned, the invention provides the bulk density of a layer to vary depending on the degree of compaction. This can be done accordingly Further features of the invention happen that the degree of compaction can be determined by mechanical action, in particular by vibration.

Furthermore, the invention allows the degree of compaction by Addition of pore formers to determine. Pore formers can be made from a reaction mixture made of lime, water and metal powder. As metal powder For example, aluminum powder or zinc powder is preferred. When using such Pore forming agent produces hydrogen, with the effect that the layer is in front of it Solidification similar to a batter, forming pores, "rises".

To make a good composite of cellulose elements or cellulose-containing To ensure elements within the layer, the invention provides that the cellulosic elements or cellulosic elements are mineralized Have surface.

According to the invention, such mineralization can be done by that the surface of the cellulosic elements or the cellulosic elements is mineralized by means of water glass. Another variant of the invention exists in that the surface of the cellulosic elements or the cellulosic Elements is mineralized by means of amorphous silicon dioxide.

Also, the invention provides in this context that the surface the cellulose elements or the cellulosic elements by means of lime milk or cemented milk is mineralized. For example, with a thin cement coating provided with shavings according to the DE 195 31 481 C1 as mineralized cellulose elements for the production according to the invention Components are used advantageously.

According to another embodiment, the invention provides that at least one layer, in particular the supporting function of the component compliant layer, with reinforcing elements, e.g. with elongated and / or grid-like reinforcing elements made of metal, plastic, Fiberglass or carbon is provided.

Also, the invention provides that as part of a broadest possible Prefabrication of components at least one layer of line elements for Containment of fluids and / or electricity.

External electrical influences (so-called "electrosmog") can be correspondingly shield the invention in that at least one layer of graphite elements, especially graphite powder.

Finally, the invention provides at least one layer of heat balance elements to add, which are able due to the Phase change, e.g. during sun exposure to absorb heat and give off heat when the sun's radiation ceases. Such elements, which consist mainly of paraffin, are under the name "PCM" (Phase Change Material) have become known and become, for example from RUBITHERM GmbH, Worthdamm 13-27, 20457 Hamburg.

In the previous description is always of two each other the adjacent layers of the speech. Of course, an inventive Component contain more than two layers, of which, however always two adjacent to each other.

The invention further relates to a method as according to the Features of the preamble of claim 18 by DE 25 48 210 B2 has become known.

As already mentioned, the known method requires a lot cumbersome method of production. According to the characteristics of the characterizing part of claim 18, this method of manufacture becomes significant simplifies that for producing a first layer the cellulosic elements and / or the cellulosic elements with all fractions of a particular one first grading that the cellulosic elements or the cellulosic Elements mixed with cement and water to a mixture be poured into the mold so that the mixture to the Increase in the degree of compaction shaken or subjected to vibration whereupon the second layer is made as a mixture, which is the grading curve cellulose elements corresponding to the first layer or another grading curve or contains cellulosic elements, as well as cement and water, and that the second layer is applied to the first layer.

Further features of the invention can be found in additional subclaims.

Fig. 1 eine schematische Längsschnittansicht eines Rütteltisches mit aufgesetzter Form zur Herstellung einer Verbundplatte,

Fig. 2 einen teilweisen Längsschnitt durch eine Außenwand,

Fig. 3 einen teilweisen Längsschnitt durch eine Bodenplatte,

Fig. 4 einen teilweisen Längsschnitt durch eine Decke,

Fig. 5 einen teilweisen Längsschnitt durch eine Dachplatte,

Fig. 6 eine grafische Darstellung der Wärmeleitzahl Lambda im Verhältnis zur Rohdichte verschiedener Materialien und

Fig. 7 die Druckfestigkeit Sigma D im Verhältnis zur Rohdichte im Vergleich verschiedene Materialien.

In the drawings preferred embodiments are shown according to the invention, it shows

1 is a schematic longitudinal sectional view of a vibrating table with attached mold for producing a composite plate,

2 is a partial longitudinal section through an outer wall,

3 is a partial longitudinal section through a bottom plate,

4 is a partial longitudinal section through a ceiling,

5 is a partial longitudinal section through a roof panel,

6 is a graphical representation of the thermal conductivity lambda in relation to the gross density of various materials and

Fig. 7 shows the compressive strength Sigma D in relation to the gross density compared different materials.

In the drawings, analogous elements are analogous to each other Always provide areas with the same reference numerals.

On a vibrating table 10, a molding box 11 is placed, which form side walls 12 and a mold bottom 13 has.

The vibrating table 10 is in a conventional manner with a vibrator or connected to another unbalance exciter, which in Fig. 1 by the with R designated two arrows symbolized.

In the open-top mold box 11 are successively two layers A and B filled, the layer thickness is denoted by S. Both Layers A and B, each one a layer of lightweight wood concrete, below "HLB", each have a mixture in the present case with the same recipe. The mixture consists of about 12 percent by weight Wood shavings consisting of approx. 45% cement by weight and approx. 43 Weight percent water.

In the molding box 11 is first a first mixture for the production filled a first layer A and pulled smooth. Then the vibrating table 10 is activated, so that the layer A is compressed. After a detail determining setting time, by prior addition of a setting accelerator, e.g. Water glass, the mixture can be shortened, the second layer B after an initial solidification of the layer A to the latter refilled. The layer B is no or only a short-term shaking movement subjected, so not compacted, so that after curing both Layers A and B, the layer A has a greater bulk density than the Layer B.

The layer B facing the surface of the layer A is denoted by FA and the layer A facing interface of the layer B is denoted by FB. Meanwhile, after pouring the flowable mixture, the layer B has become in the area of the interfaces FA and FAB one with a dashed wavy line indicated mixing zone M formed, which the two layers A and B positively and materially interconnects. In particular the cellulose elements, in the present case wood shavings, ensure a positive fit Composite within the mixing zone M.

The different densities of the layers A and B come in the present case not by a different recipe, but only due to the fact that the layer A by shaking or by vibration was mechanically compressed, while the layer B no mechanical or only a short-term compression subject.

On the other hand, it is possible in the present case, for example, the Bulk density e.g. the layer A by adding a larger proportion of cement increase.

It is also essential for layers A and B that both layers contain cellulose elements (in the present case wood shavings) corresponding to the same grading curve with all fractions of this grading curve. For example, a grading curve (sieve residue curve) was determined as follows: I II III lV V > 0 mm 0.46 g 0.46 g 1.44% 1.44% > 1 mm 1.14 g 1.60 g 3.56% 5.00% > 2 mm 9.39 g 10.99 g 29.36% 34.37% > 4 mm 19.74 g 30.73 g 61.73% 96.09% > 8 mm 1.25 g 31.98 g 3.91% 100.00%

I =

Siebgröße;

II =

Siebrückstand;

III =

Siebrückstands-Summe;

IV =

prozentualer Siebrückstand;

V =

Summen der prozentualen Siebrückstände.

Here, the Roman numerals mean the following:

I =

screen size;

II =

sieve residue;

III

Sieve residue-sum;

IV =

percentage of sieve residue;

V =

Totals of percentage sieve residues.

The table values given above represent a mean of approx. 600 screenings from wood shavings, which are then treated with a thin Cement layer according to DE 195 31 481 A1 provided - i. mineralized - were so that the so-mineralized wood shavings an intimate bond can go with the surrounding material of the respective layer A, B.

After sufficient curing, the finished composite panel component P are removed from the mold box 11 and removed. It can Such a molding box in a conventional manner with of the mold bottom 13th removable mold walls 12 may be provided.

The use of a vibrating table 10 is for the application of the invention Mixture not mandatory. Thus, e.g. Floor slabs in situ Layer by layer potted and the individual layers with mobile vibrators (so-called Rüttelbirnen example) are compacted.

The reproduced in Fig. 2 as a partial longitudinal section outer wall component E has a weatherproof layer 14 on the outside, e.g. a plaster layer on which inside a layer B (thermal barrier coating) and in more Follow a layer A (base layer) and connect a layer C.

Also in the case of this outer wall component E can, as in the embodiment according to Fig. 1, the same recipe for the layers A, B and C. be presupposed. Also, the production of the outer wall component E basically done in accordance with the type shown in Fig. 1. expedient Meanwhile, first, the layer C was poured, which is a radiation heating layer forms and flows through a heat exchange medium Embeds tubes 15.

Here, the bulk density of the layer C of the bulk density of the following poured-on support layer A correspond. Both layers C and A are obtained Accordingly, the same degree of compaction, while the thermal barrier coating B no or only a slight compression is subjected and therefore compared to the layers C and A on the lower bulk density and therefore has the greater thermal insulation capacity.

If it is appropriate for the individual application, the Thermal insulation layer B with already described above heat balance elements "PCM" (Phase Change Material) be provided.

Analogous to the composite panel component of FIG. 1 is also at the outer wall component E between the interfaces FA and FB and between the interfaces FA and FC one each with a dashed one Wavy line indicated mixing zone M present, in each of which between the individual layers B, A and C, a particularly intimate form and fabric bond consists.

In Fig. 3 is a partial longitudinal section through a bottom plate component G shown. Also, the bottom plate component G has three layers A, B and C, wherein the bulk density of the layer A to the layer C of Layer by layer gradually decreases. The points marked 16 within the layer A are to symbolize a reinforcement, which as Metal, pulp or Faserarmierung can be formed. While accordingly the layer A with the largest density and with the reinforcement 16 for the Strength of the bottom plate component G provides the layers B and C with the gradually lower density a good thermal insulation. Also in the bottom plate component G according to FIG. 4 are in the area of the boundary surfaces FA and FB as well as FB and FC form and material connection effecting Mixing zones M available.

The ceiling component D shown in FIG. 4 and the according to FIG. 5 illustrated Dachplattenbauelement DP differ from the bottom plate component G according to FIG. 4 in principle not. However, the density is the reinforcement 16 according to the individual static conditions designed differently than the corresponding reinforcement 16 of the structural panel component G (Figure 4) and ceiling tile component DP (Figure 5). Because the components D and DP otherwise the Bodenplattenbauelement G as far as possible further explanations can be dispensed with.

In Figs. 6 and 7 are physical properties of the invention Material HLB (wood lightweight concrete) compared to other materials shown.

Thus, FIG. 6 shows the thermal conductivity of various materials as the ordinate lambda [W / mK] over the abscissa gross density [kg / m ³ ].

With the material according to the invention HLB are compared to Material lightweight concrete LB (concrete with air-enclosing elements, like styrofoam and expanded clay), light hollow bricks LHZ (lattice clay bricks), aerated concrete PB (concrete with pore-forming agents in the form of aluminum and / or zinc powder) and Poroton PT (hollow expanded clay roof tile).

From Fig. 6 shows that it is possible with the material HLB according to the invention to achieve a very low thermal conductivity of about 0.05 W / mK. At a bulk density of about 1000 kg / m ³ , the material according to the invention HLB still has a relatively low thermal conductivity of 0.38 W / mK.

From FIG. 7, it can be seen that the material according to the invention has a very high compressive strength of about 10.5 N at the mentioned bulk density of 1000 kg / m ³ , which is associated with a relatively low thermal conductivity of 0.38 W / mk. mm ² features.

Finally, the material according to the invention HLB is characterized a significantly larger compared to the other aforementioned materials Bending and tensile strength.

Claims (22)

Component, in particular plate-like component (P) for use as a wall component (E), as a floor component (G), as a foundation component, as a roof component (DP), as a ceiling component (D), as a partition wall component, as a soundproofing wall component od. Like., Which at least two layers (A, B), each layer (A, B) containing cellulosic elements or cellulosic elements such as wood shavings, chips, shredded paper or the like, and wherein each layer (A, B) comprises cement as a binder and optionally contains additives, characterized in that each layer (A, B) substantially over the entire layer thickness (S) consists of a mixture of cellulosic elements or cellulosic elements of all fractions of the same grading curve that the cement evenly over the layer thickness (S ) is distributed, that the mutually facing adjacent layers (A, B) with their interfaces (FA, FB) are firmly connected to each other and that neighb rte layers (A, B) depending on the cement content or depending on the degree of compaction have different densities. Component according to Claim 1, characterized in that the adjacent layers (A, B) penetrate in the region of their mutually facing boundary surfaces (FA, FB), wherein the penetration region constitutes a mixing zone (M) forming a cohesive and positive connection. Component according to Claim 1 or according to Claim 2, characterized in that the layer (B) with the respectively lower bulk density, the thermal insulation function and the layer (A) with the respectively greater density, the supporting function of the component (P, E, G, D, DP ) Fulfills. Component according to one of claims 1 to 3, characterized in that the bulk density is additionally determined by the density of the cellulose elements or the cellulosic elements. Component according to one of claims 1 to 4, characterized in that the bulk density in addition by the addition of mineral admixtures, such as by addition of barium sulfate, can be determined. Component according to one of claims 1 to 5, characterized in that the degree of compaction by mechanical action, in particular by vibration, can be determined. Component according to one of claims 1 to 5, characterized in that the degree of compaction can be determined by adding pore formers. Component according to claim 7, characterized in that the pore-forming agent consists of a reaction mixture of lime, water and metal powder. Component according to claim 7, characterized in that the metal powder is aluminum powder or zinc powder. Component according to one of claims 1 to 9, characterized in that the cellulosic elements or the cellulosic elements have a mineralized surface. Component according to claim 10, characterized in that the surface of the cellulosic elements or of the cellulosic elements is mineralized by means of water glass. Component according to claim 10, characterized in that the surface of the cellulosic elements or of the cellulosic elements is mineralized by means of amorphous silica. Component according to claim 10, characterized in that the surface of the cellulosic elements or of the cellulosic elements is mineralized by means of lime or cementmilk. Component according to one of Claims 1 to 13, characterized in that at least one layer, in particular the layer (A) which fulfills the supporting function of the component (P, E, G, D, DP), has reinforcing elements (16), such as, for example, elongated ones and / or grid-like or mesh-like reinforcing elements made of metal, plastic, glass fiber or carbon. Component according to one of claims 1 to 14, characterized in that at least one layer (C) contains line elements (15) for the passage of fluids and / or of electric current. Component according to one of claims 1 to 15, characterized in that at least one layer contains graphite elements, in particular graphite powder. Component according to one of Claims 1 to 16, characterized in that at least one layer (B) contains PCM (Phase Change Material) elements. Method for producing a component (P), in particular a plate-like component for use as a wall component (E), as a floor component (G), as a foundation component, as a roof component (DP), as a ceiling component (D), as a partition wall component, as a soundproofing wall component od in which cellulosic elements or cellulosic elements, such as wood shavings, woodchips (shives), shredded paper or the like, cement, optionally additives and water, are introduced into a horizontally arranged mold, characterized in that for producing a first layer ( A) classifying the cellulosic elements and / or cellulosic elements with all fractions of a particular first grading curve by mixing the cellulosic elements or the cellulosic elements with cement and water to form a mixture that the mixture is filled into the mold (11) Mix is shaken to increase the degree of compaction or subjected to vibration whereupon a second layer (B) is prepared as a mixture containing cellulosic elements or cellulosic elements corresponding to the grading curve of the first layer or another grading curve, as well as cement and water, and the second layer (B) is applied to the first layer (A) becomes. A method according to claim 18, characterized - in that the first layer (A) is hardened or only partly cured before the second layer (B) is applied to the first layer (A). A method according to claim 18 or claim 19, characterized in that the mixture of the first layer (A) and / or the mixture of the second layer (B), a setting accelerator, such as water glass, we added. Component according to one of Claims 18 to 20, characterized in that a pore-forming agent is added to the mixture of at least one layer (B). Method according to one of claims 18 to 21, characterized in that prior to the preparation of the mixture, the cellulosic elements or the cellulosic elements for mineralizing their surface in intimate contact with lime, cement, amorphous silica or water glass and after hardening of the mineral surface of the mixture be added.

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