EP2155982B1

EP2155982B1 - Sandwich blocks with isolation

Info

Publication number: EP2155982B1
Application number: EP08754046.4A
Authority: EP
Inventors: Fikret Donmez
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-05-04
Filing date: 2008-04-10
Publication date: 2017-03-22
Anticipated expiration: 2028-04-10
Also published as: EA200971027A1; EP2155982A1; EA019257B1; WO2008136784A1; TR200703056A2

Description

TECHNICAL FIELD

The invention relates to the bricks with isolation used in the construction sector.
The invention relates in particular to the bricks with isolation, which are used in laying the exterior walls of the buildings and provide the heat and sound isolation.

PRIOR ART

In our country, almost every region of which encounters the low temperatures especially in the winter season and the high temperatures especially in the summer season, the failure of the bricks used in the walls of the carcass constructions to provide heat isolation leads to great losses of energy, and therefore, it has become a necessity to provide an improvement in this field. In addition, it is of great importance to isolate the individuals from the noise and the chaos of the city life and to provide them with a silent ambience at least inside their houses, by preventing the passage of sound between the flats situated side by side or one under the other in the multistorey buildings and/or between the flat and the exterior ambience.
Inability to provide isolation on the surfaces of the buildings causes an increase in the amount of energy used to heat the interior of the building during the winter. As the amount of fuel consumed to heat the interior of the building increases, both the heating expenses rise and the national resources are consumed. During the summer season, the cooling mechanisms are used at the interiors of the buildings, in order to provide protection against the high temperature outside. This practice also causes an increase in the amount of energy spent to reduce the temperature, thus it leads both to increasing expenses and to the consumption of the national resources. Considering that a significant part of the life is spent within the buildings like the houses, schools and the offices and that the energy spent to heat up and/or cool down such buildings consumes the national resources as well as causing damage to the environment and taking into account the energy bottleneck awaiting us, improvements have been realized in this field. The most widely employed method involves the subsequent coating with the isolation material, of the walls laid with the bricks made of fired clay having a structure with inner partitions. The holes present within the bricks are unfortunately not able to provide the feature of high resistance to heat permeability. In order to improve the feature of the heat permeability, the gaps at the interior are made thicker; hence the convective heat transfer takes place as a result of the circulation of the air within said gaps, and the air is brought into a state in which it carries out heat transmission, instead of heat isolation. Even though it appears at first glance that the problems is resolved, said technique is far from being practical due to the high costs and the extensive labor period. In this technique, the bricks laid to form the wall are connected to each other by means of mortar, after which they are coated with the isolation material. As a result, the expenses increase due to the costs of both the brick and the isolation material. In addition, the labor amount and the labor time needed for laying the bricks on a flat line, joining the same by drawing the mortar in between and finally carrying out the coating increase. Consequently, said method has not been able to completely resolve the present problem, because of the high costs and the extension of the time needed to complete the building.
The bricks with styropor have been developed as a result of the studies made with the aim of resolving the issue of isolation, as well as reducing the costs and the labor time. The method that is most widely used owing to its low cost involves placing the styropor panels within the gaps formed inside the bricks made from fired clay.
Although the problem of isolation has been resolved to a great extent in the walls laid with this method, it is far from being practical taking into account the long application time and the need for extra labor. In this method, the brick and the styropor are separately manufactured, and are later joined without an interval space when forming the building wall. In the walls brought together without any interval space, the problem of isolation is resolved, but this time the problem of laying the utility installations arises. When laying the installation of electricity, water, phone, etc., it becomes necessary to break the wall, this leading to unaesthetic appearances as well as extended labor times. In another practice of the bricks with isolation, after the bricks are laid on the wall in one row, the polystyrene foams with a length of 100 cm and width of 10-12 cm are placed within the slots left on the bricks during the manufacturing stage in the factory. Then the next row of bricks is laid on the previous one. In short, as each row of bricks is being laid, the worker first arranges the bricks on the row, then he places the foam between the same. This process both takes a long time and increases the costs. In another practice being the subject of the utility model document titled "brick with heat isolation" having the application number 2005/03979 , the brick with heat isolation is produced in the form of the known type of the perforated brick. There is (are) one or more than one isolation cavity inside the brick, and there is present the heat isolation element affixing protrusion on at least one side of said cavity. Considering that it is of great importance to protect the isolation material against the moisture besides the provision of the isolation, the isolation material is coated with the moisture- and water-tight materials such as nylon, propylene or polypropylene. Although said process brings about great benefits in providing the heat isolation, it is an application far from being practical and having a high cost due to its needs for extra material and labor; hence it is not preferred.
The invention being the subject of the patent document no. TR200400281A2 titled "standard thermo brick with styropored holes" is developed to solve the problems encountered in the bricks with isolation during the subsequent placement of the styropor inside the brick. The invention comprises the 5 cm-thick styropor panel placed into the standard perforated brick. Even though the joining of the brick and the panel prior to building the wall provides advantages with respect to the labor time and the labor amount needed during the building of the wall, that the brick has a perforated structure and that it is manufactured separate from styropor to be joined later on do not bring about benefits from the points of view of reducing the costs and shortening the production time. Also, the partitioned structure of the brick leads to heat loss in the isolation. Further, as the wall is being built with such type of bricks, the labor problems are encountered during the casting of the mortar between the overlapping bricks, because of the formed wall having a flat structure.
Another attempt made both to provide the sound and heat isolation and to increase the endurance of the building constructed is the invention being the subject of the utility model no. TR200601327U titled "the wall block with tunnel mould system made of expanded polystyrene". The invention is the wall block used in building constructions with its ability of being engaged to one another side by side and one on top of the other, said wall block being formed by casting concrete inside two polystyrene blocks, said polystyrene blocks being produced according to a method wherein an apparatus is formed by welding via a 90-degree cornerpiece the steels having desired diameter coming horizontally and in a parallel manner one above the other at certain intervals, with the steel rods having desired diameter coming at certain intervals perpendicularly to said steels and polystyrene blocks, said apparatus is placed into the formed mould and then the polystyrene raw material is injected into said mould by means of injection and the injected polystyrene is inflated and expanded with steam. Since the block wall according to the invention is connected by means of engagement to each other as it is being laid, it provides considerable advantage with respect to time. Unfortunately, the high cost of the materials needed to manufacture the block according to the invention makes it difficult to utilize said block. The increasing material cost automatically leads to an increase in the cost needed to lay the unit wall area, hence it makes the construction far from being economical.
The invention being the subject of the patent document no. TR200001115A2 titled "the brick without mortar" is developed taking into account the fact that one of the biggest problems encountered in today's constructions is the labor costs and labor time. The product being the subject of the invention is a construction block, which does not necessitate casting the mortar in between as being laid in a way to provide the appearance of a wall. The said invention has no feature of isolation, other than the advantages it provides with respect to the ease of application and aesthetics in appearance.
One of the applications related with prior art is numbered DE 202 10 805 U1 is titled as "insulating construction", relates to an insulating component having at least one tile made of clay or other material, two boundary walls, that are separated by boundary partitions with a number of cavities, and a layer of insulating material which is attached to at least one of the outer surfaces of the boundary walls, where the boundary wall of at least one tile, which is in contact with the layer of insulating material, has openings, wherein the dimensions of openings in the wall are different.
Another application related with prior art is numbered FR2609079 , titled as Building blocks and their method of manufacture, relates to a construction element made up of three attached layers, the central layer of which is made of insulating material whilst the outer layers are load-bearing. The central layer S1 is a solid made of insulating material prepared in advance whilst the layers located on either side are made of mortar of cement and fine sand cast against the insulating solid. Application to the building of walls and surfaces.
Today, the effort is shown to provide high isolation in the buildings by varying the brick shape as well as the materials from which it is made. A material frequently used for this purpose is silicate bims, or the pumice. Bims is preferred for such reasons as being natural, having a sustainable high performance and being cheap to obtain. During the recent years, the use of the light construction materials produced with bims aggregate is rapidly growing in the construction sector. On the other hand, is not a material which may provide high sound and heat isolation on its own. In addition to this drawback, it has a very high adherence property owing to its grained and gap-including surface. It is possible to apply both the cement- and the gypsum-based plasters in the form of a single thin coat.
Consequently, the presence of the need for the block with isolation that eliminates the disadvantages of the construction building elements used in the walls and the intermediate partitions existing in the state of the art and provides the heat and sound isolation in the exterior walls and intermediate partitions, and the inadequacy of the existing solutions have made it necessary to provide an improvement in the relevant art.

OBJECT OF THE INVENTION

Based on the state of the art, the invention aims at resolving the aforesaid existing problems.
The object of the invention is to provide high heat and sound isolation without the laid wall being coated with any other isolation material, owing to the isolation material located in the middle section of the block.
Another object of the invention is to provide a reduction in the manufacturing costs and a shortening in the manufacturing time, owing to the isolation material and the concrete with special mortar located on both sides thereof being produced at the same time and being applied as a complete system.
Another object of the invention is to provide an increase in the endurance of the building where the isolation sandwich block is applied, owing to its special design.
Another object of the invention is to provide a shortening in the time needed to build the wall, owing to the special design of the isolation sandwich block involving the engagement of the components.
Another object of the invention is to provide an increase in the field of use of the laid wall within a flat, because there is no need for an extra isolation material on said laid wall, owing to the characteristic of the isolation material positioned in the middle section of the isolation sandwich block.
Another object of the invention is to reduce the weight based on the material from which the isolation sandwich block is made and the production technique thereof and thus, to reduce the amount of labor needed during the building of the wall.
Another object of the invention is to provide the protection of the isolation material surrounded with a special mortar against the external conditions, as well as the protection of the building against the adverse weather conditions owing to said special mortar.
Another object of the invention is to provide savings from the raw material and to offer the user the chance of selection owing to the production technique of the isolation sandwich block and thus owing to the ability to manufacture the product with different size depending on the region where it is to be used.
Still another object of the invention is to provide a significant heat isolation owing to the isolation material used in the middle section and consequently, to provide a significant degree of energy savings.
Still another object of the invention is to prevent the drawbacks like cracks and breaks likely to occur as the components such as nail, screw and dowel are being struck into the wall, owing to the special structure of the isolation sandwich block.
Still another object of the invention is to provide the ability to make the inner and outer thickness of the wall that is built, with different size, owing to the specific production technique of the isolation sandwich block.
Still another object of the invention is to prevent the extra alterations needed during the placement of the installation into the wall and to provide a reduction in the needed labor and time, owing to the special partitioned structure formed within the isolation sandwich block.
Still another object of the invention is to enable the preservation of the national income and the recovery of the waste materials, owing to the ability to use the waste materials in the production of the isolation sandwich block.
Still another object of the invention is to provide economy by reducing the manufacturing costs owing to the production method and material for the isolation sandwich block.
Still another object of the invention is to enable the mortar used in joining the blocks to each other to be drawn into a specific slot and in this way, to eliminate the risk for it to be viewed from the exterior and consequently to avoid the need for plastering or whitewashing after the wall is built and as a result, to provide a reduction in the costs, owing to the special design of the isolation sandwich block wall.
The structural and characteristic features and all the advantages of the invention will be more clearly understood from the figures provided in the following and the detailed description written with reference to these figures, and therefore, the evaluation must be made taking into account these figures and the detailed description.

BRIEF DESCRIPTION OF THE FIGURES

Figure-1 is the overall schematic view of the isolation sandwich block.
Figure-2 is the overall schematic view of the isolation sandwich block including the fitting slot.
Figure-3 is the schematic view of the isolation piece in disassembled state.
Figure-4 is the overall schematic view of the isolation piece in a state assembled to each other.

REFERENCE NUMBERS

1.: Isolation sandwich block
2.: Block wall

2.1.: Mortar slot

3.: Isolation piece

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to the isolation sandwich block (1), which is used to lay the building walls and provides high heat and sound isolation as well as savings from labor and time.
The isolation sandwich block (1) shown in Figure-1 comprises the isolation piece (3) that provides the sound and heat isolation, is located in the middle section of the block (1) and is integrated with the block (1) by increasing the surface area at the side sections, and also the block wall (2) that is connected completely by means of engagement on the surface of the isolation piece (3) facing the interior and the exterior space on both sides of said isolation piece (3). Inside said isolation part (3), the partition (3.1) is formed such that it will remain in the middle section of the isolation sandwich block (1). The strength of the wall being laid is increased by placing steel construction and/or concrete into said partition (3.1). The mortar slot (2.1) is formed on the block wall (2) constituting the outer surface of said isolation piece (3). Said mortar slot (2.1) enables an easier and aesthetic application of the mortar, which is used to join the blocks (1) and to prevent the slide or dislocation from the joining points, as the wall is being built by way of placing the blocks (1) on top of another. Owing to said mortar slot (2.1), the blocks (1) may be easily connected to each other along a straight line and in a shorter time, by means of the fixation plate. Another advantage of said mortar slot (2.1) is that the mortar used to join the blocks (1) is prevented from being visible when viewed from the outside.
The fitting slots (3.2) shown in Figure-2 are designed in such a way that they will allow the placement of the fittings, being one of the two main components that constitute the reinforced concrete in the horizontal and vertical direction in the masonry buildings. Although the concrete used in the buildings is a material that functions very well against pressure, it has a low tensile strength. Owing to said fitting being placed into the fitting slots (3.2) within the isolation sandwich block (1) horizontally and vertically, the stresses in the zone of tension are covered.
As shown in Figure-3, the lock protrusions (3.3) are formed to reinforce the connection on the surfaces of said isolation piece (3) that overlap on each other. As shown in Figure-4, the isolation piece (3), which comprises 2 parts during the production, is connected to each other by means of the lock protrusions (3.3) formed on said isolation sandwich block (1), then it is placed into the mould and the mortar is cast into said mould. Then, upon the setting of the mortar, the process of cutting is performed to form the isolation sandwich block (1). Owing to the structures referred to as dovetail formed on both sides of said isolation piece (3) and having the feature of locking with inverse angle, the connection between the block wall (2) and the isolation piece (3) is reinforced.
Owing to said isolation sandwich block (1) being made of the isolation piece (3) formed in the middle section thereof and of the block walls (2) being connected with this piece (3), high heat and sound isolation is provided by a single structure, without the need for extra isolation material. Owing to the isolation feature and the size that may be designed specifically for the user, said isolation sandwich block (1) may be easily used in the regions like Turkey having different climate zones. During the production, the thickness and the size of said isolation piece (3) may be varied according to the region and the climate zone where the isolation sandwich block (1) is to be used. Thanks to the capability of changing the thickness of either the isolation piece (3) and the block wall (2) independently from each other, the endurance of the wall is increased and the duties of both the user and the inspector are made easier.
The isolation piece (3), which is located in the middle section of said isolation sandwich block (1) and has a wavy structure on the side surfaces, is coated on both sides with the block wall (2) formed from the mortar prepared by a mixture of light aggregate, cement and water. First the mortar is prepared, then it is cast into the moulds to which the isolation piece (3) is placed, thus the connection of said isolation piece (3) is provided with the block wall (2). Owing to the use of said moulds in the production, the thickness and the shape of the isolation piece (3) and also the thickness, texture and the color of the block wall (2) may be easily adjusted in the isolation sandwich block (1).
After said blocks (1) are cut in the special cutting machines, the product becomes ready for laying the wall. During the laying of the wall, the blocks (1) that are positioned by arranging the same on top of another are connected to each other by the bricklayer within a much shorter time and in an easier manner, by way of casting the adherence mortar into the mortar slot (2.1) formed on the block wall (2).
According to a preferred embodiment of the invention, an aesthetic appearance is provided by applying different colors and texture on the block wall (2) in accordance with the demand of the user, thus the need for plastering and whitewashing after the laying of the wall is eliminated and the labor time and the costs are reduced.
According to another preferred embodiment of the invention, the surface of the isolation sandwich block (1) is roughened to provide better connection between the overlapping blocks (1). Owing to said rough surface, the contact surface is increased between two blocks (1), hence the durability and the strength of the built wall are increased.
According to another preferred embodiment of the invention, said isolation piece (3) is manufactured from polystyrene rigid foam panel. However, it is also possible to use polyurethane or other isolation materials capable of high sound and heat isolation, in place of polystyrene rigid foam.

Claims

Isolation sandwich block (1), which is used in laying the exterior building walls and provides the sound and heat isolation, comprising; an isolation piece (3) positioned in the middle section of the block (1) to provide sound and heat isolation and a block wall (2) which is located during the production of the isolation sandwich block (1), on the surface on both sides of said isolation piece (3) facing the interior and the exterior space by way of coating said surfaces of said isolation piece (3) with a prepared mortar, at least one mortar slot (2.1), where the mortar is to be placed, said mortar enabling the isolation sandwich blocks (1) placed on top of another to be joined by way of putting said mortar on said block wall (2), and
- at least one fitting slot (3.2), which is formed in said isolation piece (3) and enables positioning of horizontal and vertical fittings in masonry buildings in order to cover the stresses in the tension zone.
The isolation sandwich block (1) according to Claim 1 characterized in that it comprises a partition (3.1), which is formed in said isolation piece (3), and enables to increase the strength of the laid wall and to set up the installation without causing damage to the wall, by means of the placement of the concrete or the steel construction.
The isolation sandwich block (1) according to Claim 1 characterized in that it comprises a lock protrusion (3.3), which is formed on said isolation piece (3) and enables the isolation sandwich blocks (1) positioned on top of each other to be connected to each other in a more secure manner.