EP1670734A1

EP1670734A1 - Block-type component used as a construction material for walls

Info

Publication number: EP1670734A1
Application number: EP04765729A
Authority: EP
Inventors: Wilfried Blocken
Original assignee: RECYFOAM SA
Current assignee: RECYFOAM SA
Priority date: 2003-10-02
Filing date: 2004-10-01
Publication date: 2006-06-21
Also published as: US20070266656A1; JP2007510829A; WO2005033039A1; DE112004001500A5

Abstract

The invention relates to a block-type component that is used as a construction material for walls, e.g. noise barriers and walls of buildings. Said component comprises an exterior (22) and an interior (28), in addition to a three-ply construction consisting of the following layers: an external layer (20), which consists of stone or concrete and forms the exterior (22), a central layer (24) of insulating mortar with a high degree of thermal insulation, comprising at least 70 % by vol. (in relation to the volume of the central layer) of reprocessed, granular polyurethane and cement as the binding agent and an internal layer (26) that preferably contains cement as the binding agent, said layer forming the interior (28).

Description

Description: Block-shaped building block as a building material for walls

The invention relates to a block-shaped building block as a building material for walls, for example noise barriers and building walls. The block has an outside and an inside.

The aim is to specify a building block that absorbs sound of all kinds as well as possible and has the lowest possible permeability to sound. The building block should reflect sound as little as possible, at least on the inside. Areas of application for the module are noise sources of any kind that are to be shielded from the environment, for example a residential area, for example noise sources from industrial companies, sports facilities and the like. An acoustic separation can also be carried out within a building. In general, the building block is intended for outdoor applications, e.g. free-standing noise barriers and exterior walls of buildings.

Block-shaped building blocks are generally known. There are also building blocks built up in layers, for example lightweight concrete blocks with a middle layer of foam, for example styrofoam. Gypsum boards are known for the interior, which are laminated with polystyrene boards. The object of the invention is to provide a block-shaped building block and a method for its production, from which walls can be built simply and quickly and which has the lowest possible permeability and the highest possible absorption for sound.

This object is achieved by a block-shaped module with the features of claim 1 and a method with the features of claim 14.

The module is made up of three different layers. The interior layer and / or the outer layer is either a closed layer or a layer of individual larger parts, such as bricks, normal stones, quarry stones, stone slabs (also marble, granite). In this case, the larger parts are pressed into the middle layer and preferably stick due to the cement of the middle layer. In use, these layers are positioned essentially vertically, so that sound, which spreads essentially parallel to the earth's surface, has to penetrate the individual layers one after the other. Each shift has its own role in reducing noise. The outer layer preferably has the greatest specific weight of the three layers, and is particularly responsible for blocking the sound. The middle layer has the lowest specific weight of all three layers and is responsible for the damping. The specific weight of the inner layer is preferably between the outer layer and the middle layer, it is responsible for absorption. However, the transition areas between the layers are also favorable for the intended use because the transmission properties for sound at the transition areas change.

The module also has excellent thermal insulation properties. This is due in particular to the middle layer, which has a very low thermal conductivity, its insulation value is typically 0.05 W / m K. As a result, the module has an advantageous double function. It is light and easy to handle. It is also suitable for do-it-yourselfers.

The inner layer is made of mineral grains with no fines. As a result, it is open-pored. The reflection of sound on its surface is reduced by the irregular, granular structure. The pore volume is preferably designed such that no water can collect within the structure of the inner layer, which also prevents frost damage and green growth. The middle layer is preferably chosen to be relatively thick. In any case, it contributes little to the total weight of the module, so that it can be made relatively large and yet has an acceptable total weight. The thickness of the middle layer is preferably at least twice as thick as the thickness of the inner layer and / or the thickness of the outer layer. A thickness is selected for the outer layer that is favorable for blocking the sound, without the outer layer determining too much the total weight of the building block. Layer thicknesses in the range of 4-14 cm have proven to be favorable. The inner layer is preferably at least as thick as the outer layer, preferably it is somewhat thicker than the outer layer. A grain size range of 1 - 4 mm coarse grain, for example grit, has proven to be favorable for the inner layer.

In a preferred further development, the middle layer has 90-94% by volume of reprocessed hard polyurethane, which is comminuted to a mixture of powder and granules with a particle size of preferably less than 8 mm, and 6-10% by volume of cement, in particular 92% by volume of reprocessed hard - Polyurethane and 8 vol% cement, each based on the volume of the middle layer (24).

The block-shaped component preferably has an upper and a lower side. At least one projection is provided on the upper side and the lower side has at least one recess which is at least as large as the projection on the upper side and which corresponds in shape to this projection. This makes it easy to assign the blocks to stacks. Continuous joints are avoided.

Further advantages and features of the invention emerge from the remaining claims and the following description of non-restrictive exemplary embodiments of the invention, which are explained in more detail below with reference to the drawing. In the drawing demonstrate:

1 is a perspective view of a block according to the invention,

2: an end view of a block in a second embodiment,

3 shows a perspective illustration of a building block, which is partly in section with a cutting line transverse to the longitudinal direction, in a third embodiment of the building block,

4: an end view of a module according to a fourth embodiment,

5: an end view of a block according to a fifth embodiment,

6: an end view of a module after a sixth training,

7 is a perspective view of a mold for the manufacture of the block,

8: a plan view of an upper layer, which is made of bricks,

Fig. 9: a plan view of an upper layer, which is created from field stones, and

10 shows a section along the section line XX in FIG. 9. The building block according to FIG. 1 has an outer layer 20 made of self-compacting concrete. The specific weight is typically 2400 kg / m ³ . At least 200 kg of cement is used per m ³ , preferably 300 kg of cement is used. This outer layer is a flat cuboid with a thickness of about 5 cm. The outer layer 20 forms an outer side 22 of the module. In use, this outside faces away from a noise source.

A middle layer 24 adjoins the outer layer 20. It is made from a material described in U.S. Patent 5,904,763. This material has a relatively low specific weight and in particular a very low thermal conductivity. The entire disclosure of the US patent is incorporated by reference and is part of the disclosure of the present application.

An inner layer 26 adjoins the middle layer 24 on the inside. It is also flat and cuboid. The inner layer 26 forms an inner side 28 of the module. The inner layer 24 has a specific weight of approximately 1950 to 2050 kg / m ³ . At least 100 kg of cement is used per m ³ . A proportion of 200 to 250 kg of cement is better. The inner layer has no zero fraction. The module also has a front end face 30 and a rear end face 32. Both end faces are identical, the distinction between front and back is made only for better association with the figures.

In the exemplary embodiment shown in FIG. 1, the outer layer 20 and the inner layer 26 have approximately the same thickness. The middle layer 24 has a thickness of approximately 15 cm, which is three times the thickness of the outer layer 20 or the inner layer 26. The thickness W of the module is approximately 25 cm, the length L is approximately 30-250 cm Height H is about 30 cm. All three layers 20, 24, 26 are cement-bound. Due to the similar bond, the holding of the individual layers to one another is favored. Furthermore, the resistance of the building block to environmental influences is largely determined by the cement binding. Finally, because of the bond with cement, it is possible to keep the manufacturing price of the building block low.

The block according to Figure 1 is almost, but not exactly cuboid. On the upper side, a tongue 34 is provided which extends with a constant cross section over the entire length L of the module. The cross section of the tongue is trapezoidal. The tongue 34 is formed only in the area of the middle layer 24, it extends practically over its entire width. It is limited on the one hand by short inclined surfaces 36 on both sides, which rise at an angle of 30 ° in each case. These inclined surfaces 36 begin at the interface of the middle layer 24 with the adjacent layers 20 and 26. On the other hand and essentially the tongue 34 is delimited by a main surface 38, which is located above an end surface 46 of the outer layer 20 and inner layer 26, the distance from the end surface is in the range between 0.5 and 8 cm, typically around 2-5 cm.

Corresponding to the tongue 34, a groove 40 is formed in the lower surface of the module, which essentially corresponds in shape to the tongue 34. The groove 40 is also located exclusively in the middle layer 24 and fully utilizes its width. It also extends over the entire length L. Preferably, the groove 40 has somewhat larger dimensions than the tongue 34, this makes it possible to create a space between the groove 40 and the tongue 34 when the building blocks are placed on top of one another, in order to provide an adhesive, a mortar 42 (see Figure 3) or an intermediate layer 44 (see Figure 4) to be arranged. For example, an all-round clearance of approximately 3 mm is provided between groove 40 and tongue 34. By means of the tongue 34 and the groove 40, a formal assignment of modules placed one on the other is achieved in a known manner. When building blocks are placed one on the other, the flat end faces 46 of the outer layer 20 or the inner layer 26 come into flat contact. The outer sides 22 and the inner sides 28 of blocks arranged one above the other are in alignment.

The blocks can be stacked on top of one another without gluing or connecting them in any other way. However, an adhesive or another binder can also be arranged between them. This means can only be provided between the tongue 34 and the groove 40, but it can also be provided between the end faces 46 of outer layers 20 or inner layers 26 lying one on top of the other. However, direct, direct contact of the end faces of the outer layers 20 or the inner layers 26 of modules lying one above the other is preferred. A binder is preferably applied only to the main surface 38 of the tongue 34.

A projection such as the tongue 34 and a corresponding recess such as the groove 40 do not have to be provided in principle. If they are provided, they do not have to have the concrete shape, as shown, for example insulated cylindrical projections can also be provided, which correspond to recesses on the underside, etc. Here, the prior art can be used for fitting projections and fitting recesses.

Even if it is advantageous that the projections and recesses are located only in the area of the middle layer 24, this is not a limitation, rather projections can also be provided only in the layers 20 and / or 26 or in these layers. The projections and the corresponding recesses prevent direct, straight-line joints between modules arranged one above the other. This improves overall noise insulation.

Figure 2 shows a relatively narrow block, it has a total thickness W of about 12.5 cm. The concrete outer layer 20 e.g. CEM I 52.5 is approximately 2.5 cm thick. Other concrete qualities are possible, e.g. B25 / 35th The inner layer 26, which is made of mineral grains with grain size 2-5 mm, has the same thickness. The middle layer 24 has a thickness W of approximately 7.5 cm. The stone has a height H of 20 cm and a total length L of 60 cm. Such a stone can be lifted manually, so no lifting equipment is necessary. The groove 40 on the lower surface has a depth of 2 cm, the tongue 34 on the upper side projects 1.7 cm upwards. The angle of the inclined surfaces 36 of the tongue 34 is 45 °.

In the exemplary embodiment according to FIG. 3, a stone is shown with a total width W of approximately 25 cm, it has a height H of approximately 20 cm, the length L is approximately 40 cm. In this exemplary embodiment, too, the outer layer 20 and inner layer 26 have the same thickness. The thickness is about 5 cm. The middle layer 24 fills the rest of the thickness. It is made from 80 vol% processed, reduced hard polyurethane and cement as a binder. As FIG. 3 shows, an approximately 3 mm thick layer of mortar 42 is placed on the main surface 34, through this layer there is a connection to a building block which is placed on top of the building block shown.

The module according to FIG. 4 has an overall width W of approximately 50 cm and a height H of 40 cm. It is available in three different lengths L, namely 0.6 m, 1.2 m and 1.8 m. The outer layer 20 and the inner layer 26 again have the same thickness, the thickness is approximately 10 cm, the rest of the total thickness, approximately 30 cm, is filled by the middle layer 24. This is made from reprocessed, crushed hard polyurethane with at least 85 vol% (based on the middle layer) and cement. There is again a groove 40 in the lower surface, it has a depth of 4 cm, a tongue 34 on the top protrudes 3.7 cm. An intermediate layer 44 in the form of an approximately 3 mm thick rubber strip is placed on this tongue 34, namely on its main surface 38. As a result, the gap between tongue 34 and groove 40 of two modules arranged one above the other is filled. At the same time, the acoustic and thermal properties are improved, finally the building blocks are fixed against each other by the intermediate layer 44. If a foam rubber is used for the intermediate layer 44, the thickness can also be a little over 3 mm. In the case of a compressible intermediate layer 44, its elastic property can be used.

In the embodiment according to FIG. 5, the building block has a width of 60 cm and the height is approximately 48 cm. The lengths are different, lengths of 0.6 m, 1.2 m, 1.8 m and 2.4 m total length are offered. The thickness of the outer layer 20, which is approximately 12 cm, is somewhat less than the thickness of the inner layer 26. The middle layer is approximately 36 cm thick, it is made from 90 to 94% by volume of recycled, crushed hard polyurethane, the rest being cement. In particular, it consists of 92% by volume of reprocessed, crushed hard polyurethane, grain size less than 10 mm, preferably less than or equal to 8 mm, and 8% by volume of cement.

In the embodiment according to FIG. 5, the tongue 34 protrudes relatively far upwards, the main surface 38 of the tongue 34 is 5.7 cm above the end surfaces 46 of the outer layer 20 and the inner layer 26. Accordingly, the groove 40 is also deep, its Depth is 6 cm.

The exemplary embodiment according to FIG. 6 shows a relatively wide building block, the total width W is 75 cm, the height H is 60 cm. Total lengths L of 0.6, 1.2, 1.8 and 2.4 m are also offered here. The thickness of the outer layer 20 and inner layer 26 of the same thickness are 15 cm, and accordingly the thickness of the middle layer 24 is 45 cm. The inside depth of the groove 40 is 8 cm, the height of the tongue 34 is about 7.7 cm. This module is suitable for self-supporting noise barriers that can be stacked at a sufficient height without additional proppants. Connection means between stacked blocks do not have to be provided. This simplifies the assembly and disassembly of a noise barrier.

FIG. 7 shows a mold 48 for the production of the building blocks. During production, the layers are formed with a different orientation than in later use. The layers lie horizontally, so they are one above the other in the finished block. Production generally begins with the outer layer 20, but conversely the inner layer 26 can also be created first.

As FIG. 7 shows, a suitable shape 48 is provided, which also specifies the shape of the tongue 34 and the groove 40. In other words, the shape 48 has the cavity dimensions that the finished building block also has. The form 48 is only open at the top, there is either the inside 28, which is preferred, or the outside 22. The respective top side is created by appropriate processing, for example pulling off on the upper edge of the form 48. The mold can later be opened at a suitable location (not shown) in order to demold the finished block, e.g. an end wall can be removed from the mold.

For the manufacture of the module, the mold is first filled until the bevel for the groove 40 or tongue 34 is reached. The corresponding layer is subtracted. 7 shows some areas which are formed by the shape on the finished building block (not shown in FIG. 7), namely for example 32, 34, 36, 38; this for better understanding. In the The outer layer 20 is compacted if this should be necessary.

The middle layer 24 is then introduced before the lowermost layer has hardened. A natural limitation of the thickness can also be recognized for them by the shape, namely when the bevel for the tongue 34 or the groove 40 runs out. The material of the middle layer 24 is filled in up to this level. Finally, the top layer, which is preferably the inner layer 26, is applied while the middle layer 24 has not yet hardened. A favorable connection of the layers to one another is thereby achieved.

For the production of the middle layer, reprocessed, granular polyurethane, cement and water are mixed intensively with each other, so much water is added that the mixture is pourable. Overall, more water is added than is necessary for the hardening. When the preparation for the middle layer is poured in, the surface of the middle layer evens out and water begins to drain from the mold. One now waits for a certain time, which is called the waiting time in the following. The middle layer cement should not harden during the waiting period. During the waiting time, water runs off and the cement begins to crystallize. The layer thickness becomes smaller. After typically 1 to 2 hours, generally between half an hour and five hours, the middle class shrinks. The layer thickness typically decreases by 2 to 2.5%. The running water is clean and carries practically no cement with it.

The shrinkage of the middle layer 24 is a process that is typical of the invention. The middle layer 24 originally has enough water to be able to level and order itself. It is particularly noteworthy here that the leaking water has practically nothing of the cement carries away. The shape does not have to be particularly fine-meshed to prevent cement from being carried away by water. The water-permeable form only has to have openings so small that no proportion of polyurethane can pass through the holes.

Typically, the middle layer is made as follows. 100 liters of polyurethane and 20 liters of cement (normal blast furnace cement) together with 50 liters of water are placed in a compulsory mixer, for example a construction site mixer or a screed machine. It is mixed carefully. Then another 100 liters of polyurethane, 20 liters of cement and 50 liters of water are added. It is mixed again sufficiently. The mixture obtained is pourable. It shows the setting or shrinking that is characteristic of the invention.

It is also possible to mix polyurethane and cement dry first and only then add the water. For example, you can mix 100 liters of polyurethane and 20 to 25 liters of cement dry in a screed machine and then add water. Typically, about 50% of the volume fraction of the polyurethane is added as water.

It is preferable to wait a certain time after the lower layer has been introduced into the mold. If the lower layer is a layer of concrete, you will notice a shrinkage after a certain time. As with the steps of the middle layer 24 already described, the time until the shrinkage occurs depends on the type of cement used. The time is shortened with quick cement. It is advantageous if the middle layer 24 is poured onto the lower layer as long as the lower layer is still fresh, but the cement has already hardened, that is to say the crystallization has started.

Typically, the bottom layer and the middle layer are continuous lent, that is, seamless layers. The upper layer can also be designed in this way, but it can also be designed as a layer with gaps. The latter is explained with reference to FIGS. 8 and 9.

In FIG. 8, bricks 50 or bricks are pressed into the middle layer 24 at regular intervals, they form the outer layer 20. When pressed in, the material of the middle layer 24 comes up somewhat in the gaps between the individual bricks 50, but not to the front surface of the bricks 50. The bricks 50 hold cement in the middle layer 24 through the binder, so no new binder has to be added. Addition of new binder is not excluded, for example, a thin, setting mortar layer, an adhesive layer or the like can be applied to the middle layer 24 and the bricks 50 pressed into the applied layer.

In the embodiment according to FIGS. 9 and 10, larger field stones 52 are pressed into the still fresh but already set middle layer 24. They form the outer layer 20 and the outer side 22 with their front sides. Here, too, material of the middle layer 24 comes up in the spaces between the stones 52. This can be seen in FIG. 10.

Concrete, open concrete, bricks 50, madder plaster, washed concrete, plaster, plaster, slats and any natural and prefabricated stones, such as, for example, marble slabs, concrete, paving stones, granite blocks, quarry stones 52, are suitable as outer layer 20.

Claims

Designation: Block-shaped building block as a building material for walls

1.Block-shaped building block as a building material for walls, e.g. Noise protection walls and building walls, with an outside (22) and an inside (28), characterized by a three-layer structure with the following layers: an outside layer (20) which forms the outside (22), a middle layer (24) made of insulating mortar with high thermal Insulation which has at least 70% by volume (based on the volume of the middle layer (24)) of recycled, granular polyurethane and cement as a binder and an inner layer (26) which forms the inside (28) and which preferably has cement as a binder.

2. Block-shaped building block according to claim 1, characterized in that the width of the middle layer (24) is greater than the width of the outer layer (20) and also greater than the width of the inner layer (26), preferably that the middle layer (24) has at least one thickness which is twice, in particular three times, as large as the thickness of the outer layer (20) and / or the thickness of the inner layer (26).

3. Block-shaped building block according to claim 1, characterized in that the outer layer (20) is thinner than the inner layer (26).

4. Block-shaped building block according to claim 1, characterized in that the concrete from which the outer layer (20) is made is a standardized concrete, for example CEM I 52.5, CEM I 42.5, CEM I 32.5.

5. Block-shaped building block according to claim 1, characterized in that the middle layer (24) 90-94 vol% recycled hard polyurethane, which is crushed to a mixture of powder and granules with a grain size smaller than 8 mm and 6-10 vol% Cement, in particular 92 vol% recycled hard polyurethane and 8 vol% cement, each based on the volume of the middle layer (24).

6. Block-shaped building block according to claim 1, characterized in that the thickness of the outer layer (20) is in the range between 4 and 15 cm, in particular in the range of 8-12 cm.

7. Block-shaped building block according to claim 1, characterized in that the middle layer (24) and / or the inner layer (26) are open-pore.

8. Block-shaped block according to claim 1, characterized in that it has an upper and a lower side and that on the upper side at least one projection (tongue 34) is provided and that the underside has a recess (groove 40) that at least is as large as the projection on the top and corresponds to this projection in shape.

9. Block-shaped block according to claim 1, characterized in that the block has a front and a rear end face (30, 32), both of which are flat.

10. Block-shaped block according to claim 1, characterized in that the outside (22) and / or the inside (28) are flat surfaces.

11. Block-shaped building block according to claim 1, characterized in that it has a length which is in the range from 0.4 to 2.5 m.

12. Block-shaped block according to claim 1, characterized in that a strip-shaped material (intermediate layer 44), in particular a rubber-like material, is provided which is arranged between two block-shaped blocks lying one on top of the other.

13. Block-shaped building block according to claim 1, characterized in that the outer layer (20) and / or the inner layer (26) is gapless.

14. The method for producing a block-shaped building block according to claim 1, characterized in that a lower layer, which forms the outer layer (20) or the inner layer (26), is first entered into a water-permeable form, that for the production of the middle layer (24 ) Cement, polyurethane and water are mixed and a pourable mixture is prepared which is poured onto the lower layer already in the mold, that there is a certain waiting time in which the cement does not harden yet and in which water runs out of the mold and the layer thickness of the middle layer (24) is reduced by at least 0.5%, preferably 2 to 5%, and that the upper layer, the inner layer (26) or the outer layer (20) is then applied.

15. The method according to claim 14, characterized in that when the middle layer (24) is applied to the lower layer, the latter is still fresh and / or when the upper layer is applied to the middle layer (24), the middle layer (24) is still fresh.

16. The method according to claim 15, characterized in that the application of the upper layer takes place in that parts, e.g. Bricks, field stones, are pressed in.

17. The method according to claim 14, characterized in that the waiting time is at least 30 minutes and at most 5 hours when using normally setting cement.