RU2617660C2 - Construction element for walls and wall cladding, and method of manufacturing such element - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: construction element for walls and wall cladding comprises at least one layer of the facing material and one lightweight inner layer attached by drying to the facing material to form a single unit. Said inner layer is lightweight natural lime. The nonbearing wall element and a method of manufacturing the construction element are also described.

EFFECT: creating a construction element having the advantages of natural lime while minimizing its disadvantages, including the complexity of installation and low mechanical strength.

12 cl, 4 dwg

Description

FIELD OF THE INVENTION

The invention relates to a building element for walls and wall cladding and a method for manufacturing such an element. DE 10160665 discloses one example of a building element, the characteristics of which are described in the restrictive part of claim 1.

State of the art

Natural lime is called a hydraulic solution of natural lime. It is obtained by firing marly limestones in vertical furnaces at a temperature of about 1000 ° C. Before grinding produce a long extinguishing and aging. Before laying it is enough to mix lime flour with water to obtain a homogeneous and soft paste that does not contain lumps.

In recent years, natural lime has been abandoned, using new materials instead, which are simpler to lay and more durable, since they use plasticizing additives.

But in recent years, for a number of reasons, there is a re-evaluation of natural lime.

Firstly, as the name of the material implies, natural lime is a natural product that has been known since ancient times and which has already proved its non-toxicity.

Secondly, it is a breathing material, thus preventing an increase in humidity, which can lead to an environment that is dangerous to human health.

Another reason for the more frequent use of lime is its fire resistance. Indeed, lime has a fire resistance class 1, i.e. belongs to the class of non-flammable building materials.

In addition, natural lime has a very low thermal conductivity, which is about 0.54 W / m * K.

It is thanks to the above last property that lime is used more and more often to create a heat-insulating cladding, i.e. external cladding of residential premises, in order to reduce the thermal conductivity of coated walls. For this purpose, it is often mixed with fillers having insulating properties, such as cork chips, natural or artificial fibers, for example polystyrene, and the like. Because of these mixtures of lime, this composition is generally referred to as “lightweight” because these aggregates typically have a lower specific gravity than lime.

However, the use of lightweight lime is time-consuming, since it includes at least 24 hours of drying under optimal setting conditions, and also, since the thickness of each applied layer should not exceed 2 cm. In addition, the drying time in winter should be increased.

In addition, when trying to lay a layer with a thickness of more than 2 cm at a time on vertical walls often form invisible indentations and protrusions.

For example, when creating an isolated external coating, it may be necessary to apply up to 8 cm of natural lime. This means that at least 4 layers will have to be applied.

In addition, it should be borne in mind that natural lime does not have high mechanical strength and therefore at least one reinforcing mesh is necessary to prevent the formation of cracks and edge cracks. In addition, the influence of wind and bad weather, as a rule, leads to very rapid destruction of the surface layers of lime.

Disclosure of invention

The purpose of the present invention is to provide a building element for walls and wall cladding with the advantages of natural lime, while minimizing its disadvantages, including the complexity of laying and low mechanical strength.

The object of the present invention is a building element for walls and wall linings according to claim 1 of the formula.

Another object of the present invention is a multilayer curtain wall element, created mainly using the aforementioned building element with the application of a cladding layer on the free surface of a layer of lightened natural lime.

Another objective of the present invention is the disclosure of a method of manufacturing the specified cladding element, providing a very quick receipt of this element with uniform characteristics of the layer in shape and finish.

In addition, another objective of the present invention is to disclose a method of manufacturing a wall cladding element in accordance with paragraph 9 of the formula.

The dependent claims describe preferred embodiments of the present invention, which are an integral part of the present description.

Brief Description of the Drawings

Further characteristics and advantages of the present invention will become clearer after reading the description of the preferred, but not exclusive, embodiments of the proposed wall cladding element with reference to the accompanying drawings, in which:

in FIG. 1 shows a building element according to the present invention, a sectional view in thickness;

in FIG. 2 is an embodiment of the building element of FIG. one;

in FIG. 3 is another embodiment of the building element of FIG. one;

in FIG. 4 is another embodiment of the building element shown in FIG. one.

The same elements or components in the drawings are denoted by the same reference numerals and letters.

The implementation of the invention

The cladding element 1 according to the present invention contains a first layer 11 of cladding material that must remain visible, and at least one second layer 12 of lightweight lime. This arrangement is shown in FIG. one.

According to a first embodiment of the present invention, said first layer is made of so-called “thin stone”. A thin stone consists of a very thin layer of crushed stone supported by a layer of resin; the term `` very thin layer '' means that its thickness is from a few tenths of a millimeter to several millimeters.

Such a thin stone layer is obtained by gluing a resin layer, possibly supported by a fiberglass reinforcement mesh, to the surface of natural stone, such as sandstone, lava, quartzite, etc. When the resin dries, a thin layer of stone is literally torn off the surface using an attached reinforcing mesh. The stone plate thus obtained does not have a perfectly smooth surface, but, on the contrary, is naturally rough due to its separation from other layers of the surface.

The use of thin stone has been known for some time, but has always been associated with load-bearing structures containing aluminum panels, usually hollow inside, with a honeycomb cellular structure.

Dry lime can provide the necessary support for the cladding layer. In particular, according to the present invention, it is preferable to fix the lime to the cladding layer due to the adhesive properties of the lime itself. Thus, the dried lime is naturally attached to the cladding layer.

According to the present invention, the support for thin stone is a layer of lightweight natural lime with a thickness of 1, 10, 20, 30, 40 cm or more, depending on the requirements.

Hereinafter, throughout the present description, the term `` lime '' or `` natural lime '' is used to mean lightened natural lime.

Depending on the thickness of the lime layer, one or more retaining nets 13 may be introduced into the lime layer. This principle is illustrated in FIG. 2. Reinforcing mesh 13 are known per se. They can be made of plastic or glass fiber.

According to a preferred manufacturing technique, a layer of thin stone is laid on a bearing surface, usually horizontally, and natural lime is applied to it; while it is possible to lay the retaining mesh.

Thus, a thin stone slab has a natural stone surface and a resin coated surface.

Depending on the degree of surface roughness of the resin coating, it is possible to apply the appropriate fixing compositions before laying the lime layer.

Preferred fixing compositions can be made, for example, from polyurethane, epoxy resins; they can also be two-component.

After laying a layer of lime, it can be left to dry in air or in an oven. According to the present invention, a plate is obtained that can be cut in accordance with specific requirements, forming bricks or tiles in accordance with the final aspect ratio.

Since, unlike what might be supposed, thin stone plates can have a certain degree of flexibility, the resulting building elements can have separate sections with curvature in the visible part, which can be convex or concave.

According to a second embodiment of the present invention, said first layer is made of tuff, i.e. from natural limestone.

Tufa is a very loose material, but has excellent properties due to its heat-insulating characteristics and heat capacity.

This material is used in large quantities, however, due to its fragility in quarries, large blocks of this material are cut into smaller blocks with a thickness of not more than 5-7 cm.

In order to cover the wall with tuff, thus, it is necessary to use a large amount of this material due to the difficulty of processing it. This implies obvious costs for quarrying, cutting and transportation of this material, as well as installation costs. According to the present invention, said first layer 11 of the building element can be made of tuff. A layer of lime 12 provides a sufficiently rigid support capable of preventing crushing of tuff during laying out and during loading, unloading and transport operations with the resulting building element.

According to a preferred embodiment of the invention, the thickness of the tuff layer can be reduced to a few millimeters. A possible range of thicknesses is from 3-4 mm to 20 mm or more.

According to a preferred manufacturing method, a tuff plate of thickness S is first cut and placed on a supporting surface.

A layer of natural lime is applied to the tuff layer in accordance with the previously described methods, and thus an intermediate product 1 is obtained, schematically shown in FIG. 1 or 2.

After drying the layer of natural lime, the obtained element is inverted, as a result of which the layer of lime 12 becomes a supporting element. After that, another layer of lime 12 'is applied to the tuff layer 11. The result is intermediate 1b, as shown in FIG. 3.

After drying the second layer of natural lime 12 ', the obtained element is cut in the direction perpendicular to the thickness S of the element, in the middle part r of the tuff layer 11.

Thus, two building elements 1 are obtained, each of thickness S / 2.

According to another embodiment of the present invention, another tuff layer 11 ′ may be applied to the free surface of the lime layer 12, preferably before the lime layer has hardened so as to create a uniform element. This principle is illustrated using FIG. 4. The resulting element in its structure really resembles a sandwich, since a layer of lightweight lime 12 is located between two layers of tuff. This option is especially suitable for creating curtain walls, partition walls and various partitions.

According to the present invention, a multiplex sandwich may contain several layers of lime with layers of tuff located between them.

According to a preferred embodiment of the method for manufacturing curtain wall elements, a multiplexed sandwich is preventively produced and then cut in a direction perpendicular to the thickness S of the sandwich, in the middle part r of each tuff layer, as shown in FIG. 3. Thus, several elements of a curtain wall can be obtained simultaneously. It is advisable to transport this sandwich using a conveyor belt to make a cut horizontally - parallel to the direction of movement of the conveyor. The support created by lime allows using modern means of production to make the thickness of the layers of tuff lining less than 2 mm.

A preferred method of manufacturing a sandwich sandwich may allow the application of the upper layers after the lower layers of lime have already partially dried.

Any openings for water pipes and wiring can be created already at the stage of production of curtain wall elements according to the present invention.

Channels for water pipes and wiring can indeed be created in a layer of lime, thereby greatly simplifying the subsequent stages of the production of a building element. These solutions, for example, cannot be used when using exclusively aluminum panels of a honeycomb design as supporting elements, since there is no placeholder for creating channels.

On the other hand, by combining the cladding layer 11 with the supporting honeycomb aluminum panels and lightweight lime layers, it is possible to obtain a tile suitable for creating floors and surfaces for decoration. In this case, the preliminary creation of water channels in the lime layer allows you to create a heated floor with heating.

The option of a building element coated with tuff is especially advantageous due to the properties of tuff, in particular its friability, since it is easy to carry out operations and give it the desired shape in place without the use of special equipment. Thus, thanks to the present invention, excessive friability of this material is transformed into its advantage.

So, according to the present invention:

- tuff is lined with building elements in order to create a more or less uniform wall;

- inserts and decoration can be made in these walls;

- on the tuff layer in order to increase its strength, resins, paint or water-repellent compositions can be applied.

Such resins and paints are known per se.

According to the present invention, the coating on the obtained element can preferably be carried out using lime, resulting in a composition of the type of "lime on lime" without the use of additional adhesives or additional mechanical components that lead to a violation of thermal insulation.

Limestone has a rough surface, so you can avoid the use of any fixatives on the interface between limestone and lime.

After laying, the layer of facing material 11, whether it is a thin stone, but rather a tufa or ceramic or terracotta tile, is visible.

According to the present invention, it is preferable to apply natural lime when it is already in a thickened state in order to reduce setting time, which is too long due to the fact that various layers of lime need to dry. In addition, the use of slightly thickened lime allows the use of loose material such as thin stone or thin plates of natural tuff, which would be impossible to use without the support.

Moreover, since the specific gravity of light lime is lower than that of tuff, the building element according to the present invention is lighter than a traditional tuff block of the same size. Among other things, its heat-insulating properties are better than that of simple tuff.

Another advantage provided by the present invention is that, in addition to excellent physicomechanical properties, natural lime is much more economical in terms of the final cost of the material and transportation costs, since it is usually transported in bags.

Honeycomb aluminum panels, expensive in their own right, lose in terms of weight to volume, which has a significant impact on transportation costs.

The use of aluminum panels of honeycomb construction to increase the rigidity of the above-described building element is also possible in the manufacture of building elements of large sizes, for example, a solid wall or a significant part thereof. According to one preferred embodiment of the present invention, one or more of the retention nets can be replaced with aluminum panels of a honeycomb structure.

In this case, the honeycomb aluminum panels can be placed between the layer 11 and the lime layer 12 or inside the lime layer 12.

According to another aspect of the present invention, the combination of lightweight lime and tuff allows you to get an advantageous combination of thermodynamic characteristics both in thermal insulation and heat capacity. In addition, a significant improvement in sound insulation was noted due to the significant physical and mechanical heterogeneity of the two materials.

In accordance with another preferred embodiment of the present invention, it is possible to obtain a building module made up of two building elements, in which a layer of lime is enclosed inside and only the corresponding layers of the cladding are visible from the outside.

This solution is optimal, first of all, in the production of removable monoblocks and street walls.

The elements and characteristics described above for various preferred embodiments may be combined with each other provided that they do not fall outside the scope of protection of this application.

Claims (21)

1. A building element for walls and wall cladding containing at least one layer of cladding material (11) and one lightweight inner layer attached to the cladding material (11) by drying to form a single block, characterized in that said inner layer is lightweight natural lime (12). 2. An element according to claim 1, wherein said layer of facing material (11) contains a thin sandstone plate with a thickness of several tenths of a millimeter to several millimeters. 3. The element according to claim 2, wherein said thin plate is obtained by tearing. 4. The element according to claim 1, wherein said facing material is tuff (limestone) with a thickness of more than 3-4 mm. 5. The element according to claim 1, in which the specified facing material is a ceramic tile or similar element. 6. The item according to any one of paragraphs. 1-5, in which between the specified layer of cladding (11) and the specified layer of lightened natural lime (12) applied fixing composition. 7. The item according to any one of paragraphs. 1-5, in which the thickness of the specified layer of light natural lime (12) is more than 1 cm 8. An element according to claim 6, in which the thickness of said layer of lightened natural lime (12) is more than 1 cm. 9. A curtain wall element comprising a first layer of facing material (11) and a second layer of facing material (11 ') with at least one layer of lightweight natural lime (12) between them, dried and forming a sandwich structure. 10. A method of manufacturing a building element according to any one of paragraphs. 1-9, comprising at least the following steps: - preparation of the cladding layer (11), - the location of the specified layer of cladding (11) in the horizontal plane, - applying a layer of lightened natural lime (12), - drying the specified layer of lightened natural lime (12). 11. The method according to p. 10, further comprising the step of inserting according to at least one reinforcing reinforcing mesh (13) with a lime layer thickness (12) and / or the step of preparing the fixing composition and applying it to the cladding layer (11) before applying the lime layer (12). 12. The method according to any one of paragraphs. 10-11, further comprising performing the following operations after drying: - turning over the received element, - application of an additional layer of lightened natural lime (12 '), - drying the specified additional layer of lightened natural lime (12 '), - cutting the resulting element in a direction perpendicular to the thickness (S) of the element along the corresponding middle part (r) of the cladding layer (11).

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