NZ753849B2 - Residential block and method for producing a thermal insulation - Google Patents
Residential block and method for producing a thermal insulation Download PDFInfo
- Publication number
- NZ753849B2 NZ753849B2 NZ753849A NZ75384917A NZ753849B2 NZ 753849 B2 NZ753849 B2 NZ 753849B2 NZ 753849 A NZ753849 A NZ 753849A NZ 75384917 A NZ75384917 A NZ 75384917A NZ 753849 B2 NZ753849 B2 NZ 753849B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- wall
- exterior
- room
- foam
- core
- Prior art date
Links
- 238000009413 insulation Methods 0.000 title claims abstract description 54
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 6
- 239000006260 foam Substances 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims abstract description 18
- 230000004888 barrier function Effects 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000004814 polyurethane Substances 0.000 description 5
- 229920002635 polyurethane Polymers 0.000 description 5
- 239000000835 fiber Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000011490 mineral wool Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 239000010440 gypsum Substances 0.000 description 3
- 229910052602 gypsum Inorganic materials 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 238000009833 condensation Methods 0.000 description 2
- 230000005494 condensation Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000013013 elastic material Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000004965 Silica aerogel Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000001580 bacterial effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000006263 elastomeric foam Substances 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000002937 thermal insulation foam Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B1/34815—Elements not integrated in a skeleton
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B1/34815—Elements not integrated in a skeleton
- E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/99—Room acoustics, i.e. forms of, or arrangements in, rooms for influencing or directing sound
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/72—Non-load-bearing walls of elements of relatively thin form with respect to the thickness of the wall
- E04B2/723—Non-load-bearing walls of elements of relatively thin form with respect to the thickness of the wall constituted of gypsum elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B2001/34892—Means allowing access to the units, e.g. stairs or cantilevered gangways
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B2001/742—Use of special materials; Materials having special structures or shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
- E04F2290/02—Specially adapted covering, lining or flooring elements not otherwise provided for for accommodating service installations or utility lines, e.g. heating conduits, electrical lines, lighting devices or service outlets
- E04F2290/023—Specially adapted covering, lining or flooring elements not otherwise provided for for accommodating service installations or utility lines, e.g. heating conduits, electrical lines, lighting devices or service outlets for heating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
- E04H1/12—Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles
- E04H2001/1283—Small buildings of the ISO containers type
Abstract
method for producing a thermal insulation (5) between a dry wall room wall (14) of a cuboid interior space (3) and an exterior wall (8) that is parallel to the room wall, the cuboid interior space having an edge length of at least 2m respectively and the exterior wall configured at a cuboid container which envelopes the interior space (3). The method comprising the steps: initially attaching an interior surface of the dry wall room wall that is oriented towards the interior space at a core by a vacuum and positioning the interior surface together with the core parallel to the exterior wall before injecting a curing foam, supporting an exterior surface of the exterior wall that is oriented towards an exterior ambient of the container by a support device perpendicular to the interior surface. Curing foam is injected between the dry wall room wall and the exterior wall while the dry wall room wall is attached at the core by the vacuum and while the exterior surface of the exterior wall is supported by the support device. After the foam is cured, the core is removed from the interior surface and the support device is removed from the exterior surface. The thermal insulation forms a substructure that stabilizes the dry wall. ner which envelopes the interior space (3). The method comprising the steps: initially attaching an interior surface of the dry wall room wall that is oriented towards the interior space at a core by a vacuum and positioning the interior surface together with the core parallel to the exterior wall before injecting a curing foam, supporting an exterior surface of the exterior wall that is oriented towards an exterior ambient of the container by a support device perpendicular to the interior surface. Curing foam is injected between the dry wall room wall and the exterior wall while the dry wall room wall is attached at the core by the vacuum and while the exterior surface of the exterior wall is supported by the support device. After the foam is cured, the core is removed from the interior surface and the support device is removed from the exterior surface. The thermal insulation forms a substructure that stabilizes the dry wall.
Description
RESIDENTIAL BLOCK AND METHOD FOR PRODUCING A THERMAL INSULATION
The invention relates to an habitation block comprising habitation levels that are
arranged on top of each other, wherein at least one of the habitation levels includes
adjacent habitation units; an outer shell formed as a cuboid container that includes a
placement surface, a cover, up to two lateral walls and up to two face walls, a cuboid
interior space which has an edge length of at least two meters respectively, a walkable
base with step soundproofing, a room ceiling, and up to four room walls with an
intermediary space formed between the lid and the walls, and on the other hand side
between the room ceiling and the room walls, and with a monolithic thermal insulation in
the intermediary space.
The invention also relates to a method for producing a thermal insulation between a
room wall of a cuboid interior space and an exterior wall that is parallel to the room wall,
wherein the interior space has an edge length of two meters respectively and the
interior wall is configured at a cuboid container which envelopes the interior space, and
wherein initially an interior surface of the room wall that is oriented towards the interior
space is attached at a core and positioned together with the core parallel to the exterior
wall before injecting the foam, and an exterior surface of the exterior wall that is oriented
towards an exterior ambient of the container and supported by a support device
perpendicular to the interior surface, and then a curing foam is injected between the
room wall and the interior wall, and after curing the foam, the core is removed from the
interior surface and the support device is removed from the exterior surface.
The step soundproofing decouples the base mechanically from the placement surface
of the outer shell and thus prevents a transmission of walking sounds to adjacent, in
particular lower habitation units.
Sea containers also designated as ISO containers, in particular according to ISO 668,
are standardized, cuboid, large containers made from steel that facilitate simple and
quick loading, transporting and storing of goods.
Upcycling used sea containers into habitation units requires high quality insulation of the
interior in order to provide a high level of habitation quality and on the other hand side in
order to minimize energy consumption when used for habitation. In order to prevent
thermal bridges caused by metal connections as well as caused by gaps, monolithic
thermal insulations, thus thermal insulations that are made from one piece and that are
joined without gaps, are being used that support the floor, the room ceiling, and the
room walls.
DE 20 2008 002 754 U1 proposes a habitation block made from recycled ISO steel
containers with a thermal insulation made from prefabricated insulation plates. In
practical applications thermal bridges cannot be avoided between prefabricated
insulation plates. Condensation water collects at in inside of the containers, in particular
when the inside of the container forms an outer skin of the habitation block, wherein the
condensation water causes bacterial growth and impairs the thermal insulation.
GB 2472761 A proposes to spray thermal insulation made from hard polyurethane foam
onto an interior of the walls in a habitation unit made from a recycled ISO steel
container, imbed support elements into the insulation and bolt the base, the room ceiling
and the room walls to the support elements. The support elements embedded into the
thermal insulation degrade the effectiveness of the thermal insulation in particular spots.
DE 2 221 486 A proposes a camping trailer superstructure with an inner shell from glass
fiber-reinforced PE resin constructed on a core and constructing a mold around the
inner shell and filling a cavity with PU foam providing thermal insulation and building an
outer shell in turn from glass fiber-reinforced PE resin after removing the mold.
EP 0 367 275 A1, US 6,920,996 B1 propose to fabricate sidewalls, roof and floor of an
isolated container initially individually as a “sandwich” and then join it or arrange
spacers between the inner shell and the outer shell or.
US 5,733,582 A furthermore proposes fabricating an insulated container by clamping
the container and a prefabricated inner shell between an outer support frame and a
mandrel and tilting the container in various directions in order to let the still liquid
thermal insulation foam flow in the respective desired direction. The support of the
room wall and the external wall effectively prevents their deformation. The core
additionally performs the function of a handling tool for the room wall. This makes
attaching the room wall at the external wall before injecting the foam redundant.
Furthermore, DE 32 08 302 A1 proposes to used stacked sea containers for habitation
purposes.
OBJECT
Thus it is an object of the invention to improve thermal insulation of the habitation unit.
SOLUTION
Improving upon the known habitation block, it is proposed according to the invention
that the thermal insulation completely fills the intermediary space and is glued together
with the room walls. The gluing replaces the substructure for supporting the dry walls
which is performed in classic drywall construction by wooden supports or metal profiles,
and attaches the room ceilings and the room walls at the substructure by form locking
and friction locking connectors like bolts or nails. In particular, the thermal insulation
can be injected into the intermediary space, wherein the thermal insulation is glued
together full surface with the room ceiling and the room walls, or the room ceiling and
the room walls can be glued subsequently onto the thermal insulation. Also mixed
embodiments are conceivable.
Advantageously the thermal insulation of a habitation block according to the invention is
made in particular from a closed pore polyurethane hard foam. The thermal insulation
then contributes to a mechanical stability of the room ceiling and the room wall.
Alternatively the thermal insulation can essentially be made from a pouring or a
pourable material, e.g. wood fibers, expanded glass, Perlite or an amorphous silica
aerogel with a foaming and hardening or fixing component.
The thermal insulation can also be put together in layer from a combination of the
recited materials.
The thermal insulation can additionally include at least one layer made from a vacuum
insulation panel (VIP panel). The thermal insulation then has a particularly high
insulation value.
Advantageously the room walls and/or the room ceiling in a habitation block according
to the invention include at least one layer made from an elastic material, in particular an
open pore elastomeric foam or a mineral wool in plate form. The elastic material
prevents a transmission of body sound between the shell and the interior cavity.
Advantageously the room walls, the floor and the room ceiling of the habitation unit in a
habitation block according to the invention have a minerally bonded cover layer on an
inside that is oriented towards the inner cavity. A minerally bonded cover layer, in
particular from dry wall, cardboard or fiber plates facilitates furnishing the interior space
with well-known affordable technologies. Alternatively the base, the room walls and the
room ceiling can also be configured from a wood material, e.g. from three layer plates.
Also mixed forms are conceivable.
In particular the base of the habitation unit according to the invention can include a dry
screed. When the dry screed has a surface area weight of at least 50 kg/m it
simultaneously functions as a thermal buffer and thus reduces the thermal requirements
of the habitation unit.
In a habitation block according to the invention the room walls, the floor and the room
ceiling of the habitation unit can include a vapor barrier layer on an outside that is
oriented towards the thermal insulation. The vapor barrier significantly reduces
moisture absorption of the thermal insulation, in particular of a hydroscopic
polyurethane hard foam through the room wall and thus retains the insulating properties
of the thermal insulation.
Advantageously the floor of the habitation unit in the habitation block according to the
invention includes a floor heating. The floor heating avoids additional heat radiators
and provides a particularly high level of habitation comfort. Alternatively also the room
walls or the room ceilings can be configured as heating surfaces. Also mixed forms are
conceivable.
Advantageously the shell of the habitation unit in the habitation block according to the
invention is an sea container. In particular used sea containers are available in large
and increasing numbers as an economical raw material and are characterized by a very
robust, in particular very weather resistant surface and can be reintroduced into the
material cycle even after a secondary use of many years providing a valuable raw
material.
Further advantageously the shell of the habitation unit in a habitation block according to
the invention has a length of approximately 12 m and a height of approximately 2.9 m.
A 12.025 m container of this type (so called high cube or HC container) facilitates a
usable habitation surface of up to 26 square meters. Alternatively sea container with a
length of 6.096m can be used for smaller habitation units and for larger units containers
with a length of 13.716 m or 16.154 m can be used or with a height of approximately 2.6
meters for a complex floor and ceiling configuration of the habitation area.
Advantageously the outer shell and the room walls of the habitation unit in a habitation
block according to the invention are interrupted by a door opening and/or window
opening so that the inner space is connected with an outer environment of the shell.
Alternatively a habitation unit according to the invention can also be accessed by stairs
or by an elevator from below through the placement surface or from above through the
cover. Also mixed forms are conceivable.
In a habitation block according to the invention the thermal insulation of the habitation
unit as a matter of principle does not fill the door or window openings nor openings in
the outer shell for stairs, elevators and discharge and supply conduits. In the context
of this application these openings are not designated as part of the outer shell and the
volumes connecting thereto in inward direction are not designated as part of the
intermediary space.
Advantageously the outer shell of the habitation unit in a habitation block according to
the invention includes a pass through that extends at a face side parallel to the face
side and the interior space is separated from the pass through by a divider wall.
Integrating the pass through into the outer shell simplifies combining several of the
habitation units. Alternatively or additionally a habitation unit of this type can include
an outward open terrace or a balcony at the same face side or at an opposite face side.
Advantageously the interior spaces of the adjacent habitation units in a habitation level
of the habitation block according to the invention are connected with each other through
the interrupted shells and room walls. Connected rooms are created by combining the
habitation units, wherein a habitation surface of the connected rooms exceeds the
space provided in a single container.
Advantageously the pass through openings of adjacent habitation units adjoin each
other in a habitation level of this type and form a common alley way.
Further advantageously hallways of habitation levels that are arranged on top of each
other in a habitation block according to the invention are connected by stair cases
and/or elevators. Habitation units according to the invention that are arranged
adjacent to each other and above each other can also be accessed by an independent
accessory structure. Also mixed configurations are conceivable.
Improving upon the known method it is proposed according to the invention that the
room wall is attached to the core by vacuum. The attachment of plate shaped building
elements by vacuum at handling devices is well known from handling of OSB, three
layer and particle boards in carpentry applications. After injecting and curing the foam
the room wall is disengaged from the core by removing the vacuum from the core.
Advantageously the foam is injected according to the invention in layers that extend
vertically on top of each other. According to the method according to the invention the
foam fills uneven spots in the surface of the respective lower layer and levels them
under the effect of gravity after the injection. Alternatively the foam is injected
simultaneously from plural horizontally adjacent nozzles according to the method
according to the invention wherein the nozzles move back and forth in the longitudinal
direction of the room wall during the injection and are thus raised continuously.
Advantageously the foam is injected simultaneously between a second room wall and a
second exterior wall according to the method according to the invention, wherein the
room wall is arranged in the interior space opposite to the second room wall and the
exterior wall is configured at the container opposite to the second room wall. Thus, the
core and the support device are supported relative to each other during injection of the
foam. Thus, the method according to the invention makes an external support as well
as a support of the core or of the support device redundant.
Advantageously the foam according to the method according to the invention is injected
after producing the thermal insulation between the room wall and the outer wall between
a room ceiling that terminates the room in upward direction and a cover that terminates
the container in upward direction. The method according to the invention thus also
facilitates a thermal insulation of the room ceiling.
Advantageously injecting foam between the room wall and the exterior wall is
documented according to the method according to the invention by a camera. Thus,
the method according to the invention is documented for quality control of the thermal
insulation.
Advantageously a method according to the invention is used when producing a
habitation unit for the habitation block described supra. The method according to the
invention facilitates an industrial fabrication of a habitation unit with high dimensional
precision which significantly simplifies interior construction of the habitation unit.
Embodiments
The invention is subsequently described with reference to embodiments. The first
habitation unit 1 according to the invention illustrated in the drawing figure includes an
outer shell 2 made from a 12.025m HC sea container and a cuboid interior space 3 and
an interior space 4 with thermal insulation 5 between the shell 2 and the interior space
The outer shell 2 includes a horizontally extending placement surface 6 and there above
and parallel to the placement surface 6, a cover 7, two side walls 8 and two face walls
9, 10. The side walls 8 are interrupted by two door openings 11 and the front face wall
9 is provided as a fall safety. The interior space 3 includes a walkable floor 12 and
there above in parallel to the floor 12 a room ceiling 13 and four vertical room walls 14,
The room walls 14, 15, the floor 12 and the room ceiling 13 respectively include gypsum
fiber plates as a minerally bonded cover layer which is defined towards the thermal
insulation 5 by a pressure resistant vapor barrier 16 made from aluminum.
In order to produce the habitation unit 1 the room walls 14, 15 and the room ceiling 13
are attached by vacuum at a non-illustrated core and inserted with the core into the
previously emptied shell 2. The shell 2 is clamped from an outside in a support device
that is not illustrated either.
Then a polyurethane hard foam is injected for the thermal insulation 5 with a pressure
above 200 bar by two spraying devices that are not illustrated wherein the injecting is
initially performed simultaneously between two room walls 14, 15 and the shell 2 in
layers that extend vertically above one another and subsequently the insulation is
injected in adjacent layers between the room ceiling 13 and the shell 2.
After curing the thermal insulation 5 the vacuum is removed, the core is separated from
the from the room walls 14, 15 and room ceiling 13. The room walls 14, 15 are moved
towards each other, the core is removed from the interior space 3 and the clamping in
the support device is disengaged.
After installation of the floor 12 with a plate shaped prefabricated thermal insulation,
walking noise insulation and floor heating 18 the habitation unit is ready for interior
finishing.
The interior space 4 is phoned with a monolithic thermal insulation 5 made from
polyurethane hard foam between the cover 7 and the room ceiling 13 and between the
side walls 8 and the rear face wall 10 and the room walls 14 and is thus completely filled
without any gaps. The thermal insulation 5 is glued with its entire surface with the room
ceiling 13 and with the room walls 14 as well as with the shell 2 and furthermore
envelops the front room wall 15 of the inner space 3 wherein the front room wall 15
simultaneously forms a divider wall 19 to a pass through 20 between the two door
openings 11 that is integrated into the habitation unit 1.
The interior space 3 of the habitation unit 1 according to the invention has a useable
habitation surface of 9.5 m x 2.2m = 20.9 m , with a room height 21 of 2.4 m. The
habitation unit 1 according to the invention has excellent sound insulation properties,
complies with the passive house energy standard and is recyclable to a large extent.
Several habitation units 1 can be arranged adjacent to each other so that the door
openings 11’ of adjacent habitation units match and the pass through alleys 20 form a
common covered walking alley.
A second, third, fourth and fifth habitation unit that is produced according to the
invention is not illustrated but substantially corresponds to the first habitation unit 1.
The second habitation unit does not have a pass through for a walking alley but a
useable habitation surface of 12 meters x 2.2 meters = 26.4 m The third habitation
unit is provided for installation in a stack of habitation units produced according to the
invention and has no thermal insulation between the placement surface and the floor
and between the cover and the room ceiling.
The fourth and fifth habitation unit do not have a vapor barrier but an elastic layer made
from mineral wool that is connected with the gypsum fiber plate and sound decouples
the interior space from the shell and thus from the environment or adjacent habitation
units. In the fourth habitation unit the polyurethane hard foam is directly adjacent to the
mineral wool, the fifth habitation unit includes a prefabricated double gypsum fiber plate
with an intermediary layer made from the mineral wool which simplifies handling.
REFERENCE NUMERALS AND DESIGNATIONS
1 habitation unit
2 outer shell
3 interior space
4 intermediary space
thermal insulation
6 placement surface
7 cover
8 wall
9 front face wall
rear face wall
11 door opening
12 walkable floor
13 room ceiling
14 room wall
front room wall
16 vapor barrier
17 walking sound insulation
18 floor heating
19 divider wall
pass through opening
21 room height
PATENT
Claims (5)
1. A method for producing a thermal insulation (5) between a dry wall room wall (14) of a cuboid interior space (3) and an exterior wall (8) that is parallel to the room wall (14), wherein the cuboid interior space (3) has an edge length of at least 2 m respectively and the exterior wall (8) is configured at a cuboid container which envelopes the interior space (3), the method comprising the steps: initially attaching an interior surface of the dry wall room wall (14) that is oriented towards the interior space (3) at a core by a vacuum and positioning the interior surface together with the core parallel to the exterior wall (8) before injecting a curing foam, and supporting an exterior surface of the exterior wall (8) that is oriented towards an exterior ambient of the container by a support device perpendicular to the interior surface, and thereafter injecting the curing foam between the dry wall room wall (14) and the exterior wall (8) while the dry wall room wall is attached at the core by the vacuum and while the exterior surface of the exterior wall is supported by the support device, and after curing the foam, removing the core from the interior surface and removing the support device from the exterior surface, wherein the thermal insulation (5) forms a substructure that stabilizes the dry wall.
2. The method according to claim 1, characterized in that the foam is injected in layers that are arranged vertically on top of each other.
3. The method according to claim 1, wherein the foam is simultaneously injected between a second dry wall room wall and a second exterior wall, wherein the room wall (14) is arranged in the interior space (3) opposite to the second dry wall room wall (14) and the exterior wall (8) is configured at the container opposite to the second exterior wall (8).
4. The method according to claim 1 , characterized in that the foam is subsequently injected between a room ceiling (13) that terminates the room in upward direction and a cover (7) that terminates the container in the upward direction.
5. The method according to claim 1, characterized in that injecting the foam between the room wall (14) and the exterior wall (8) is documented by a camera.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE202016106380.9 | 2016-11-15 | ||
DE202016106380.9U DE202016106380U1 (en) | 2016-11-15 | 2016-11-15 | apartment |
DE102017116939.3 | 2017-07-26 | ||
DE102017116939.3A DE102017116939A1 (en) | 2017-07-26 | 2017-07-26 | Method for producing a thermal insulation |
PCT/EP2017/001334 WO2018091137A1 (en) | 2016-11-15 | 2017-11-15 | Residential block and method for producing a thermal insulation |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ753849A NZ753849A (en) | 2020-11-27 |
NZ753849B2 true NZ753849B2 (en) | 2021-03-02 |
Family
ID=
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