EP3730710A1 - Improved block - Google Patents

Abstract

The invention relates to a component (1) comprising one or more frames (4), on which a first single or multilayer planking (5) on a first surface and a second single or multilayer planking (6) on a second surface are arranged, wherein between the first and the second cladding (5, 6) a thermal insulation (10) and / or sound insulation made of a foamed plastic foam is arranged, which is formed in one piece.

Description

The invention relates to a component comprising one or more frames, on which a first single-layer or multi-layer paneling is arranged on a first surface and a second single-layer or multi-layer paneling is arranged on a second surface, with one between the first and the second paneling Heat and / or sound insulation is arranged from a foamed plastic foam.

The invention also relates to a construction module comprising a module body which is composed of several components.

The invention further relates to a method for producing a component comprising the steps of: providing a frame or multiple frames, arranging a first single-layer or multi-layer paneling on a first surface of the frame or frames, arranging a second single-layer or multi-layer paneling on a second Surface of the frame or the frame, arrangement of thermal and / or sound insulation made of a plastic foam between the first and the second cladding.

In addition, the invention relates to a method for producing a construction module with a module body which is composed of several components.

The use of wood frame wall elements in prefabricated house manufacture is known from the prior art, for example DE 100 55 480 A1 or the DE 199 29 969 A1 . These wall elements usually consist of a wooden frame that is planked in at least one layer on both sides. In order to achieve sufficient thermal insulation, thermal insulation, a so-called core insulation, is arranged between the cladding. The types of thermal insulation and the materials used for this are different. In addition to natural materials, foams made from various polymers such as polystyrene or polyurethane are also used. This insulation is usually installed as sheet material, or a mixture of polymer particles with a binding agent, for example polystyrene beads mixed with cement, is blown in. The latter is often used for floor elements. Blowing in insulating material has the advantage, if processed correctly, that practically no cavities, i.e. imperfections, are formed. The disadvantage here, however, is the long production time, so that "quick construction" is only possible if the prefabricated house supplier has the appropriate production capacities.

The present invention is based on the object of providing an improved method for producing a thermally insulated prefabricated house and a corresponding structural element for it or a corresponding prefabricated house.

In the context of the invention, the term prefabricated house is not limited to a residential building per se. Rather, it is understood to mean a building that has a floor, walls and a ceiling or a roof.

The object of the invention is achieved with the component mentioned at the beginning, in which the thermal and / or sound insulation is formed in one piece.

The object of the invention is also achieved by a construction module which is formed from one or more components according to the invention.

Furthermore, the object of the invention is achieved with the method mentioned at the beginning, according to which it is provided that a foamable mass is poured into the cavity or cavities formed by the first and second planking and the frame and the plastic foam is foamed in the cavity or cavities becomes.

In addition, the object of the invention is achieved by the above-mentioned method for producing a construction module, according to which one or more, preferably all, components of the construction module are produced according to the invention.

The advantage here is that the production of thermally insulated components can take place significantly faster, since the plastic foam can be foamed and cured in a relatively short time. In addition, the process is relatively dry, which means that the component can be processed further after a short time. It is thus possible to shorten the throughput times for the production of such components and the prefabricated houses formed from them.

According to an embodiment variant of the invention, it can be provided that the thermal and / or sound insulation is connected directly to the first and / or the second paneling and / or the frame. On the one hand, the connection improves the bond strength of the component itself, since it enables the two panels to be connected to one another, and on the other hand, the direct connection means that an additional adhesive and thus an additional work step can be dispensed with.

However, according to a further embodiment variant of the invention, it can be provided that the first and / or the second paneling has at least one film on the surface facing the heat and / or sound insulation. The foil can be used to better prevent foam material from penetrating into one of the panels during foaming, which can cause a disruption in the formation of the foam structure.

According to a variant of the construction module, it can be provided that the thermal insulation and / or sound insulation is formed in one piece between the frame of the module body. Thermal bridges can thus be avoided better. In addition, the manufacturing time for the construction module can be further shortened. In addition, the structural strength of the building module can be improved in this way, since the plastic foam (having adhesive properties) can extend completely continuously and in one piece. According to a variant of the method for producing the building module, it can be provided for this that the thermal insulation and / or sound insulation is first filled into the cavities formed by the first and second panels and the frames and the plastic foam is foamed in the cavities after the frame all components (1) have been assembled to the construction module.

For a more homogeneous formation of the foam structure, it can be advantageous according to an embodiment variant of the method if the foamable mass is sprayed into the cavity of the component or poured in with a casting tool.

In the preferred embodiment, a polyurethane foam is produced using at least one polyol and at least one isocyanate, since thermoset polyurethane foams have very good thermal insulation properties and the wall thicknesses can thus be kept low compared to other insulating components.

This in turn is advantageous with regard to a complete and homogeneous filling of the hollow space of the component.

According to further variant embodiments, it can be provided that the at least one polyol is used at a temperature that is selected from a range from 35 ° C. to 50 ° C. and / or that the at least one isocyanate is used at a temperature that is selected from a range of 38 ° C to 60 ° C. This significant preheating of the components for producing the thermal insulation can ensure that the foaming takes place more quickly. As a result, it can be achieved that the rising foam exerts a significantly smaller lateral pressure force, whereby the wall elements are subject to less bulging as a result of the foaming pressure. Preferably, however, the curing time is not shortened, so that the formation of voids in the foam structure can be better avoided. In addition, it has been shown that if the plastic foam is allowed to cure for a longer period of time, the plastic foam, which was previously foamed rapidly, begins to shrink, which can compensate for the slight bulge that is present.

According to a further variant of the process, it can be provided that the at least one isocyanate is used at a temperature which is 3 ° C. to 10 ° C. higher than the temperature at which the at least one polyol is used. In the course of the evaluation of the invention it was namely found that the just described behavior of the reaction mass can be further improved.

For a better understanding of the invention, it is explained in more detail with reference to the following figure.

Fig. 1

einen Ausschnitt aus einem Fertighaus in Holzrahmenbauweise;

Fig. 2

ein Baumodul.

It shows in a simplified, schematic representation:

Fig. 1

a section from a prefabricated house in timber frame construction;

Fig. 2

a building module.

By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component designations, the disclosures contained in the entire description correspondingly referring to the same Parts with the same reference numbers or the same component names can be transferred. The position details chosen in the description, such as for example top, bottom, side, etc., refer to the figure immediately described and shown and these position details are to be transferred accordingly to the new position in the event of a change in position.

In Fig. 1 a section from a prefabricated house is shown. Specifically shows Fig. 1 two components 1 of the prefabricated house in the form of an outer wall element 2 and an adjoining floor element 3. It should be noted, however, that the in Fig. 1 The components 1 shown specifically serve only to illustrate the invention and are not of a restrictive nature with regard to the invention.

The component 1 according to the invention is used in a timber frame house construction (also referred to as a timber frame construction). Accordingly, the component 1 can also be referred to as a wooden frame component. It comprises at least one frame 4. In Fig. 1 the frame 4 is only partially shown in order to have a better insight into the internal structure of the component 1. On the frame 4 or the frame 4, a first surface and a second surface 5, 6 are fastened to a first surface. The frame 4 is or the frames 4 are preferably arranged between the first and the second cladding 5, 6.

The component 1 can form a wall or the floor or a floor ceiling of a prefabricated house in its entirety or together with other components 1. In the event that several components 1 are used, all components 1 are preferably designed with the frame 4 and the panels 5, 6. The use of several structural elements 1 to build a wall or the floor or a floor ceiling is known per se in timber frame construction.

The cladding 5, 6 can have several cladding elements, for example wooden boards, optionally with tongue and groove, wood-based panels, plasterboard, etc. Of course, the respective requirements must be taken into account. For example, no plasterboard is used on the outside. Accordingly, the cladding 5 can be designed differently or identical to the cladding 6, depending on where the component 1 is installed in a prefabricated house.

Furthermore, at least one of the panels 5, 6 can be designed in one or more layers. In the embodiment variant shown, the outer paneling of the wall element 2 is designed in two layers, with a cavity 7 being formed between the two layers for forming a ventilated panel 5. On the room side, the planking 6 is shown with only one layer. However, this does not mean that the planking 6 cannot also have several layers on the room side.

In addition, there is the possibility that the panel (s) 5, 6 are arranged protruding at least on one side over the frame 4.

The frame 4 is formed by several horizontal and vertical profiled wood elements 8, 9 which are connected to one another at frame corners. The horizontal profiled timber elements 8 (in Fig. 1 only the lower horizontal profile element 8 is shown) the threshold or the bolt and the vertical profile wood elements 9 the uprights of the frame 4.

In the simplest case, the profiled timber elements 8, 9 are designed as square timbers. However, they can also have a more complex cross-sectional shape, for example be provided with grooves for receiving sealing elements. In general, the profiled wood elements 8, 9 are preferably designed as solid wood elements. But they can also be designed as so-called glue binder elements, for example.

The floor element 3 can also be designed as a structural element 1 with a frame 4 made of profiled wood elements 8, 9 (which of course are not referred to here as a threshold, bolt or stand) with single or double-sided single or multi-layer planking 5, 6.

Next can also be designed as components 1 according to the invention for interior walls or floor ceilings of prefabricated houses.

A cavity is formed by the frame 4 and the panels 5, 6. A thermal insulation 10 (also referred to as a thermal insulation element) is arranged in this cavity. Instead of the thermal insulation 10, sound insulation can also be arranged, wherein the thermal insulation 10 can also have sound-absorbing properties. The thermal insulation 10 is formed from a foamed plastic foam.

In Fig. 2 a construction module 11 is shown. The building module 11 is composed of several components 1, which form walls 12, a floor 13 and a ceiling 14 or a roof of the building module 11. For better illustration of the invention, the first and the second paneling 5, 6 are only partially shown.

The building module 11 can be a complete building by itself, e.g. form an office or a residential building. However, it is also possible for several of these building modules 11 to be combined to form a building, one building module 11 for example forming only one room in the building.

Each of the components 11 has at least one frame 4. Whose or their profiled wood elements 8, 9 each form a component of the walls 12, the floor 13 and the ceiling 14 or the roof. The aforementioned cavity 7 is formed between two frames 4 and the two panels 5, 6. Only the two end walls 15 (in Fig. 2 the front and the rear wall 12 of the building module 11) can each be designed with only one frame 4, so that the above explanations apply to these end walls 15 Fig. 1 can be transferred.

It should be mentioned in this context that the building module 11 can also have only one or no end wall 15, in particular if several building modules 11 are combined into a single room. In this case too, however, the frame 4 of the missing end wall 15 / end walls 15 can optionally be present.

The cavity 7 or the cavities 7 between each two frames 4 preferably extends continuously over the entire circumference of the construction module 11. In this way, the thermal insulation 10 and / or sound insulation between the frame 4 can also be formed entirely in one piece, whereby thermal bridges can be avoided. Thermal insulation 10 and / or sound insulation can thus be provided, which extends monolithically between the profiled timber elements 8, 9 of the frame over the ceiling 14, at least one, preferably both, walls 12 and the floor 13 (= completely in one piece). The thermal insulation 10 and / or sound insulation can therefore be constructed from only one-piece "ring elements".

If the prefabricated house has several floors, the thermal insulation 10 and / or sound insulation can extend between the monolithic profiled wood elements 8, 9 of the frames of several floors. However, it can also be provided that when the ceiling 14 or floor 13 is adjacent to one another, only one of these two components has the thermal insulation 10 and / or sound insulation.

To produce the thermal insulation 10 and / or sound insulation, the frame or frames 4 is / are first provided. Thereafter, the first skin 5 is fastened to a first surface and the second skin 6 is fastened to a second surface of the frame 4 / the frame 4. This creates the aforementioned cavity between the frame (s) 4 and the two panels 5, 6. A foamable mass is then poured into this cavity and foamed. The thermal insulation 10 and / or sound insulation is thus produced in the component 1 or in the construction module 11 itself. This is preferably done in the factory in which the components 1 or the construction module 11 are / will be manufactured. The thermal insulation 10 and / or sound insulation can also be produced on the construction site. In the event that the cavity formed by the frame or frames 4 and the two skins 5, 6 is completely closed, appropriate openings 16 are made for the introduction of the foamable compound ( Fig. 2 ) formed in one of the panels 5, 6 or the frame 4, which can be closed again after foaming. For example, a cladding element, for example a wooden board or wood-based material board, can only be mounted on the frame 4 or the frame 4 subsequently, ie after the production of the thermal insulation 10 and / or the sound insulation.

By foaming the thermal insulation 10 and / or sound insulation in the cavity formed by the frame 4 and the two panels 5, 6, this is at least 95%, in particular at least 98%, preferably entirely, with the thermal insulation 10 and / or sound insulation filled in, this being formed in one piece. The one-piece design can be limited to one wall element, as is the case, for example, with the end walls 15, or it can be designed entirely, as has already been described above.

The foaming of the foamable mass in said cavity has the advantage, in addition to the good and quick volume filling, that empty piping or installation lines can be easily arranged and foamed in this cavity. There is no need to cut out finished thermal insulation elements.

According to one embodiment variant of the invention, the thermal insulation 10 and / or sound insulation can be connected directly to the first and / or the second paneling 5, 6 and / or the frame 4. For this purpose, the adhesive force of the foamable mass or the plastic foam produced from it can be used. Due to the direct connection to the first and / or the second planking 5, 6 and / or the frame 4, an additional stiffening or stiffening of the component 1 can be achieved without an additional work step for the introduction of an adhesive being necessary.

According to a further embodiment variant of the invention, it can be provided that the first and / or the second cladding 5, 6 has at least one film on the surface facing the thermal insulation 10 and / or sound insulation. This film can have one or more layers. In particular, the film is designed to be vapor diffusion-open in at least one direction (in particular in the direction of the surroundings of the prefabricated house) so that moisture can better escape from the wall structure. This can also be of particular advantage if water is required for the reaction of the foamable mass or is created in the process.

The foamable mass can be injected into the cavity formed by the frame 4 and the two panels 5, 6, for example with lances. According to a variant embodiment of the method, the foamable mass can be poured into this cavity with a casting tool. The foamable mass can be injected or sprayed in with medium or high pressure pumps. A high pressure spray process is preferably used.

The pressure for introducing the foamable mass into the cavity or cavities can be between 45 bar and 175 bar.

In principle, any suitable foamable mass can be used to fill the cavity formed by the frame 4 and the two panels 5, 6, this foamable mass preferably not being a heterogeneous mixture with, for example, foam particles, etc.

In the preferred embodiment, the thermal insulation 10 and / or the sound insulation is a hard foam. A rigid foam is a foam which opposes a deformation with a compressive strength of at least 0.07 N / mm ² , in particular at least 0.1 N / mm ² .
Furthermore, the thermal insulation 10 and / or the sound insulation is preferably a closed-cell, duromer foam, ie it has a proportion of at least 90%, preferably at least 95%, closed cells.

According to a preferred embodiment of the invention, the plastic foam is a polyurethane foam and is therefore made from at least one polyol and at least one isocyanate.

The isocyanate can be a toluene diisocyanate (TDI), for example a toluene-2,4-diisocyanate, or a diphenylmethane diisocyanate (MDI). A diphenylmethane-4,4'-diisocyanate is preferably used which has an NCO content between 30% by weight and 35% by weight. With regard to the processing of the isocyanate, it is also advantageous if the isocyanate has a viscosity at 25 ° C. between 150 mPa s and 600 mPa s, in particular between 160 mPa s and 300 mPa s. For example, an isocyanate with the name Desmodur ® from Covestro can be used as the isocyanate, preferably Desmodur ® 44V20L.

A polyester polyol or a polyether polyol can be used as the polyol. A polyether polyol is preferably used. In particular, a polyol with a viscosity at 25 ° C. between 400 mPa s and 550 mPa s, preferably between 460 mPa s and 525 mPa s, is used. The polyol can also have a hydroxyl number between 50 mg KOH / g and 400 mg KOH / g. For example, a polyol with the name Baymer® from Covestro can be used as the polyol, preferably Baymer® AL 737.

The polyol can already contain a blowing agent, for example based on a fluorinated hydrocarbon. The blowing agent can, however, also be mixed separately with the foamable mass.

The polyol is preferably used with the isocyanate in a weight ratio of polyol: isocyanate between 100: 101 and 100: 110.

Furthermore, the foamable mass for PUR foam can contain conventional additives, such as a catalyst or a fire-retardant additive.
The foamable mass is preferably processed as a 2-component system, although the use of a 1-component system is possible.

According to a preferred embodiment variant, the at least one polyol is used with a temperature which is selected from a range from 35 ° C to 60 ° C, in particular between 35.1 ° C and 52 ° C, preferably between 35.1 ° C and 45 ° C , 1 ° C.

Furthermore, according to a further preferred embodiment, it can be provided that the at least one isocyanate is used at a temperature which is selected from a range from 38 ° C to 70 ° C, in particular between 38 ° C and 60 ° C, preferably between 38 ° C and 52 ° C.

It is particularly preferred to combine these last two variants of the processing temperatures of the polyol and the isocyanate with one another. Rapid foaming of the foamable mass in the cavity formed by the frame or frames 4 and the panels 5, 6 can thus be achieved. In this way, it can be better avoided that elements of the panels 5, 6 become detached or that the panels 5, 6 bulge out too much. The rapid foaming enables the plastic foam to rise more quickly, which means that the lateral pressure force that causes the wall elements to bulge can be reduced. A slight bulging of the panels 5, 6 can, however, be permitted, since the shrinkage behavior that begins when the reaction mass sets and hardens causes the bulging to decrease again.

For this reason, according to another variant of the process, it can be provided that the at least one isocyanate is used at a temperature which is 3 ° C. to 10 ° C. higher than the temperature at which the at least one polyol is used.

In general, the polyol and the isocyanate can be introduced into a casting installation for pouring the foamable mass by means of pumps, in particular medium and high-pressure pumps.

Embodiment:
A frame 4 for a structural element 1 was made from spruce square timbers. This frame was then planked on one surface with a customary exterior cladding made of spruce and with a thickness of 2 cm. Pressboard panels were used for the second planking 6 on the second surface of the frame 4.

A mixture of Baymer® AL 737 and Desmodur® 44V20L (weight ratio 100: 101) was used in the cavity formed. The Baymer ® AL 737 was preheated to a temperature between 35.1 ° C and 45.1 ° C and the Desmodur ® 44V20L to a temperature between 38 ° C and 52 ° C.

This mixture was then poured into the cavity. During a time between 30 s and 120 s, in particular between 50 s and 70 s, the mass foams. The foamed mass is then cured for a time between 150 s and 400 s, in particular between 200 s and 240 s.

After completion of the thermal insulation 10, there were no bulging areas on the paneling.

The exemplary embodiments show or describe possible design variants of the component 1, the construction module 11 and the method for their production, it being noted at this point that combinations of the individual design variants with one another are also possible.

For the sake of clarity, it should finally be pointed out that for a better understanding of the structure of the component 1 or the construction module, these or their components are not necessarily shown to scale.

List of reference symbols

1

Component

2

Exterior wall element

3

Floor element

4th

frame

5

planking

6th

planking

7th

cavity

8th

Profiled wood element

9

Profiled wood element

10

Thermal insulation

11

Building module

12

wall

13th

ground

14th

ceiling

15th

Front wall

16

breakthrough

Claims (13)

Component (1) comprising one or more frames (4) on which a first single or multi-layer planking (5) is arranged on a first surface and a second single or multi-layer planking (6) is arranged on a second surface, wherein A thermal insulation (10) and / or sound insulation made of a foamed plastic foam is arranged between the first and second cladding (5, 6), characterized in that the thermal insulation (10) and / or sound insulation is formed in one piece. Component (1) according to claim 1, characterized in that the thermal insulation (10) and / or sound insulation is connected directly to the first and / or the second planking (5, 6) and / or the frame (4). Component (1) according to claim 1 or 2, characterized in that the first and / or the second cladding (5, 6) has at least one film on the surface facing the thermal insulation (10) and / or sound insulation. Construction module (11) comprising a module body which is composed of several structural elements (1), characterized in that one or several, preferably all, structural elements (1) are designed in accordance with one of Claims 1 to 3. Construction module (11) according to Claim 4, characterized in that the thermal insulation (10) and / or sound insulation between the frame (4) of the module body is formed in one piece. A method for manufacturing a component (1) comprising the steps: - Provision of a frame (4) or several frames (4), - Arrangement of a first single or multi-layer planking (5) on a first surface of the frame (4) or the frame (4), - Arrangement of a second single or multilayer planking (6) on a second surface of the frame (4) or the frame (4), - Arrangement of thermal insulation (10) and / or sound insulation made of a plastic foam between the first and second cladding (5, 6), characterized in that
a foamable mass is filled into the cavity or cavities formed by the first and second cladding (5, 6) and the frame (4) and the plastic foam is foamed in the cavity or cavities. Method according to Claim 6, characterized in that the foamable mass is poured or sprayed into the cavity of the component (1). Method according to Claim 6 or 7, characterized in that the plastic foam is produced from at least one polyol and at least one isocyanate. Process according to Claim 8, characterized in that the at least one polyol is used at a temperature which is selected from a range from 35 ° C to 60 ° C. Process according to Claim 8 or 9, characterized in that the at least one isocyanate is used at a temperature which is selected from a range from 38 ° C to 70 ° C. Process according to one of Claims 6 to 10, characterized in that the at least one isocyanate is used at a temperature which is 3 ° C to 10 ° C higher than the temperature at which the at least one polyol is used. Method for producing a building module (11) with a module body which is composed of several components (1), characterized in that one or more, preferably all, of the components (1) are produced according to one of claims 6 to 11. Method according to claim 12, characterized in that the thermal insulation (10) and / or sound insulation is only filled into the cavities formed by the first and second panels (5, 6) and the frames (4) and the plastic foam is foamed in the cavities after the frames (4) of all components (1) have been mounted to the building module (11).

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