EP2860323B1 - Building element - Google Patents

Description

The invention relates to a component consisting of a sandwich-like material composite which is constructed of at least two cover layers and at least one honeycomb structure arranged between the cover layers.

Sandwich panels with a honeycomb structure are known in the art. For example, the German Offenlegungsschrift discloses DE 10 2007 034 544 A1 a lightweight board with at least two cover layers and a middle layer of a cardboard honeycomb or cardboard honeycomb. The lightweight board can be used in addition to the furniture and interior design in areas of building services or in ship, rail vehicle, motor vehicle and aircraft. The lightweight board described has a heat resistance class 2. In particular in shipbuilding and aircraft construction, the requirements for fire protection have increased in recent years. This is due to the fact that, for example, cruise ships are getting bigger and thereby increase the number of passengers. However, the above-mentioned lightweight board does not meet the applicable in particular shipbuilding fire safety requirements (SOLAS regulations, Safety of Life at Sea) for A- and B-class walls.

From the DE 694 24 403 T2 there is known a refractory plate which comprises a laminate of at least one layer of a layer of glass fibers impregnated with at least one refractory phenol-formaldehyde resin. According to embodiment, in addition, a honeycomb structure made of metal, which as a carrier of the corresponding layers Glass fibers used, be provided. Although this known composite material meets the requirements according to the SOLAS regulations (A-60), it is disadvantageous that it is composed of many layers which require several process steps and thus can not be produced inexpensively from today's perspective.

From the EP 0 568 270 A1 For example, a composite panel having first and second layers and a core of a fibrous material is known. In the cells of the core is a mixture of inorganic insulating material and a material that releases water at elevated temperature. Today's fire protection panels (sandwich panels), in particular the fire classification (SOLAS) A-60 and B-15, consist of a non-flammable core, usually of a pressed, highly compacted mineral wool, which has a cover of steel or fiber-reinforced magnesite screed on both sides. The high density material is relatively heavy. Although the overall weight can be reduced by using magnesite screed instead of steel cover sheets, the sound insulation of such fire protection wall elements is not optimally designed, in particular in view of the increased comfort requirements of travelers on cruise liners.

Based on this, the present invention seeks to provide a device of the type mentioned, which meets at least the fire protection class B, is relatively light, acoustically optimized, stable and durable, and can be relatively inexpensively.

To solve this problem, a component with the features of claim 1 is proposed.

The device according to the invention is made of a sandwich-like material composite, which is arranged at least from two cover layers and at least one between the cover layers Honeycomb structure is constructed. According to the invention, the honeycomb structure is formed from a material which contains at least one inorganic and at least one organic fiber, at least one inorganic filler and in each case at least one inorganic and organic binder. The honeycomb material of the non-combustible component comprises in addition to the at least one inorganic fiber, for example mineral fiber, in particular rockwool fiber and / or ceramic fiber and the at least one organic fiber, for example cellulose fiber in combination with at least one inorganic filler, for example mineral filler, preferably a hydrated aluminum silicate, colloquially also called "kaolin", also at least one inorganic binder, preferably water glass and at least one organic binder, preferably a polymer dispersion, in order to obtain a solid and workable material, in particular as a flat product. Tests have shown that such a honeycomb material can withstand continuous use temperatures of up to 1,000 ° C. The shape of a honeycomb form of, for example, a flat semi-finished product is known from the prior art. In combination with the metallic cover layers can be a very stable and due to the high volume of air in the honeycomb structure also an acoustically optimized component especially for walls, partitions and ceilings for preferably ships, aircraft or oil rigs but also as building elements, the drywall, in brand- and explosive areas, such as in fuel storage and chemical laboratories, and also in elevators, especially elevator cars. Incidentally, the metallic cover layers or cover plates of the According to the invention, the components are designed to be relatively thin, so that a reduction of the weight of the sandwich material or of the component made therefrom is also possible in comparison to known designs.

The device according to the invention fulfills at least the fire protection class B, sometimes even the fire protection class A according to SOLAS, since the organic content (binder and fibers) of the honeycomb material to a maximum of 3.0 wt .-%, in particular to a maximum of 2.5 wt .-%, preferably is limited to a maximum of 2.0 wt .-% based on the weight of the honeycomb material.

The thickness of the respective cover layer of the component according to the invention is, for example, in the range of about 0.1 mm to 1.5 mm, preferably in the range of about 0.2 mm to 1.0 mm, and particularly preferably in the range of about 0 , 25 mm to 0.8 mm.

The cover layers of the component according to the invention are preferably made of steel material. Steel material is a relatively inexpensive material, which is characterized by a high temperature resistance and a high breaking strength.

Non-ferrous metals such as aluminum or copper are suitable as cover layers for the device according to the invention. Aluminum has the advantage that forms on the free surface with temperature increase (in case of fire) in the ambient atmosphere, a layer of alumina, which is resistant to high temperatures.

In order to achieve favorable material costs and at the same time a long service life of the component according to the invention, a further embodiment of the invention provides that the cover plates are provided with a corrosion protection layer. The corrosion protection layer is realized, for example, by refining and / or electrolytic coating of the metal cover sheets. Characteristic coatings for the refining are: Z: 99% Zn, ZA: 95% Zn + 5% Al; AZ: 5% Al + 43.4% Zn + 1.6% Si; AS: 88-92% Al + 8-12% Si. A further advantageous embodiment of the device according to the invention is characterized in that the cover plates are provided with different thicknesses and / or with different corrosion protection layers. As a result, it is possible to achieve a component which is optimal in terms of high flexural rigidity, low component weight and high weather resistance for, inter alia, maritime use.

According to a further embodiment of the device according to the invention, at least its visible side is additionally provided with an organic coating. Organic coatings in the form of paints can have different colors, so that there are no limits to the color design of the component according to the invention.

To achieve a sufficiently high temperature resistance, the honeycomb core of the device according to the invention in a further embodiment of the invention, a height in the range of about 5 mm to 100 mm, preferably in the range of about 10 mm to 80 mm, and particularly preferably in the range of about 20 mm to 60 mm.

The honeycomb material of the component according to the invention preferably contains a mineral fire retardant, which is halogen-free and acts as a flue gas suppression agent. This is advantageous when using the component according to the invention as a wall and / or ceiling element in closed rooms. An unnecessary additional health damage can be prevented. Further, the honeycomb material may preferably contain a fungicide which suppresses mold formation in the core.

For connecting the layers of the sandwich-type composite material, a further embodiment of the component according to the invention provides that the respective cover layer is connected to the honeycomb structure via an adhesive layer. The adhesive used is preferably an aqueous-based adhesive, for example a polyurethane dispersion adhesive or heat-seal adhesive. The layer thickness of the respective adhesive layer is for example in the range of 5 microns to 25 microns, preferably in the range of 8 microns to 15 microns. The application of the adhesive to the cover layer, for example, by doctoring, spraying or coating by applicator roll. The cover layers (cover sheets) as well as the honeycomb core can be connected to one another in a band-shaped or tabular form. Preferably, the connection of the cover layers with the core layer by means of a Laminating. The adhesive applied to the cover layer (eg heat-seal adhesive) is activated in the laminating system by pressure and temperature and crosslinked with the honeycomb structure.

Alternatively, an aqueous-based adhesive may already be introduced into the honeycomb material during the production of the honeycomb material, in particular it may be infiltrated or admixed. As a result, the step of applying the adhesive to the cover layers can be omitted. The connection of the cover layers with the honeycomb structure, as already described above, preferably takes place in a laminating system in which the adhesive in the region of the adjacent cover layers is first activated and crosslinked by pressure and temperature and adheres cohesively or simultaneously to the cover layers.

According to a further embodiment of the device according to the invention, the honeycomb may be additionally filled with inorganic, non-combustible airborne sound absorber elements, such as expanded glass granules or expanded glass. These can lead to a slightly increased weight of the device according to the invention at a relatively low density, but this improves the acoustics and possibly the thermal insulation.

Alternatively or additionally, a thin, preferably with a thickness of up to 0.3 mm micro-perforated absorber can be integrated in the device to improve the acoustics. The thin microperforated absorber is preferably placed centrally in the device according to the invention in order to be able to effectively develop its effect.

Further preferred and advantageous embodiments of the device according to the invention are specified in the subclaims.

Fig. 1

zeigt, vor seiner Fertigstellung, ein erfindungsgemäßes Bauelement in perspektivischer Darstellung;

Fig. 2

ein erstes erfindungsgemäßes Bauelement in Schnittdarstellung; und

Fig. 3

ein zweites erfindungsgemäßes Bauelement in Schnittdarstellung.

The invention will be explained in more detail below with reference to a drawing showing two exemplary embodiments:

Fig. 1

shows, before its completion, an inventive component in perspective view;

Fig. 2

a first inventive component in a sectional view; and

Fig. 3

a second inventive component in a sectional view.

Fig. 1 shows a state before the completion of a device according to the invention. The cover layers 1.1, 1.2 consist for example of sheet steel, which is preferably provided with a corrosion protection layer. Preference is given to zinc or aluminum based corrosion protection layers are used. The thickness of the respective cover layer (cover plate) 1.1, 1.2 is for example about 0.1 to 1.5 mm, preferably at most 1.0 mm, particularly preferably at most 0.8 mm. In the in Fig. 1 shown embodiment, both cover sheets 1.1, 1.2 have substantially the same thickness, for example, about 0.3 mm, and have the same material quality. But it can also cover sheets 1.1, 1.2 different thickness and / or material quality for the production of the sandwich-like composite material 2 are used.

The material of the honeycomb structure 2 contains a mixture of inorganic fibers, preferably mineral fibers, and inorganic filler, preferably mineral fillers, with a small proportion of organic fibers and binder. The inorganic fibers, which together with the inorganic filler constitute the main constituent of the honeycomb material, are preferably bio-soluble mineral fibers. In addition, the honeycomb material may contain a mineral, halogen-free fire retardant, which has a high flue gas suppression effect. Since the proportion of organic fibers and organic binder in the honeycomb structure 2 is very low, at most 3.0% by weight, in particular at most 2.5% by weight, preferably at most 2.0% by weight, based on the weight of the Honeycomb material, resulting in a fire or heat as good as no flue gas development. The honeycomb structure 2 has a height of 5 to 100 mm, preferably 10 to 80 mm, and particularly preferably in the range of about 20 to 60 mm. The edge lengths of the hexagonal honeycomb structure are preferably the same length.

The inorganic fibers and mineral fillers of the honeycomb core 2 enable such a honeycomb material to withstand continuous use temperatures up to 900 ° C or even up to 1000 ° C, preferably non-flammable. In addition, the honeycomb structure 2 has a good heat insulation and good soundproofing.

The cover layers 1.1, 1.2 are bonded by gluing to the core layer. For this purpose, for example, one side of the respective cover layer 1.1, 1.2, namely the honeycomb structure of the second facing side, coated with adhesive. The adhesive is preferably an aqueous-based adhesive, for example polyurethane dispersion adhesive. For a sufficient connection of top layer 1.1, 1.2 and honeycomb structure 2, the adhesive is applied, for example, with a layer thickness between 5 to 25 .mu.m, preferably between 8 to 15 .mu.m on the cover layer 1.1, 1.2. The application of the adhesive can be done for example by spraying, doctoring or by application rollers. The connection of cover layers 1.1, 1.2 and honeycomb structure 2 (in Fig. 1 indicated by arrows) is then preferably by means of a heated laminating (not shown), activated in the pressure and temperature of the adhesive and the cover layers 1.1, 1.2 and the honeycomb structure 2 are materially interconnected ( Fig. 2 ).

The device 3 "in Fig. 3 is different from the one in Fig. 2 illustrated component 3 'characterized in that a microperforated absorber 4 is arranged as a middle layer in the component 3 ", which contributes to the improvement of the acoustics.The absorber 4 is connected on both sides with a honeycomb structure 2.1, 2.2, in turn, with cover layers 1.1, 1.2 are connected.

The in the FIGS. 2 and 3 shown in section components 3 ', 3 "serve as wall and / or ceiling elements for buildings, in particular office buildings or public buildings, eg in airports, or ships, aircraft or oil rigs.

The embodiment of the invention is not limited to the embodiments shown in the drawing.

On the contrary, numerous variants of the component 3 'according to the invention are conceivable which make use of the invention specified in the appended claims, even in embodiments which deviate from the illustrated embodiments.

Claims (9)

1. Building element (3', 3") consisting of a sandwich-like material composite which is built up at least from two metallic cover layers (1.1, 1.2) and at least one honeycomb structure (2, 2.1, 2.2) arranged between the cover layers, characterized in that the honeycomb structure (2, 2.1, 2.2) is formed from a material which contains at least one inorganic and at least one organic fibre, at least one inorganic filler and in each case at least one inorganic and organic binder, wherein the organic content of the honeycomb material is at most 3.0% by weight.
2. Building element according to Claim 1, characterized in that the honeycomb structure (2, 2.1, 2.2) comprises a thickness in the range from 5 mm to 100 mm, preferably in the range from 10 mm to 80 mm, particularly preferably in the range from 20 mm to 60 mm.
3. Building element according to Claim 1 or 2, characterized in that the cover layers (1.1, 1.2) are produced from steel material.
4. Building element according to one of Claims 1 to 3, characterized in that the cover layers (1.1, 1.2) are provided with a corrosion protection layer.
5. Building element according to one of Claims 1 to 4, characterized in that the respective cover layer (1.1, 1.2) comprises a thickness in the range from 0.1 mm to 1.5 mm, preferably in the range from 0.2 mm to 1.0 mm, particularly preferably in the range from 0.25 mm to 0.8 mm.
6. Building element according to one of Claims 1 to 5, characterized in that the cover layers (1.1, 1.2) are of different thickness and/or are provided with different corrosion protection layers.
7. Building element according to one of Claims 1 to 6, characterized in that the respective cover layer (1.1, 1.2) is connected to the honeycomb core (2) via an adhesive layer.
8. Building element according to Claim 7, characterized in that the respective adhesive layer is formed from aqueous-based adhesive, preferably from polyurethane dispersion adhesive.
9. Building element according to Claim 7 or 8, characterized in that the respective adhesive layer comprises a layer thickness in the range from 5 µm to 25 µm, preferably in the range from 8 µm to 15 µm.

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