SE540562C2

SE540562C2 - Strengthened pre-shaped insulation elements

Info

Publication number: SE540562C2
Application number: SE1630015A
Authority: SE
Inventors: Palmu Henrik
Original assignee: Jackon As
Priority date: 2016-01-27
Filing date: 2016-01-27
Publication date: 2018-10-02
Also published as: SE1630015A1; NO20170120A1

Abstract

:The invention comprises a method and device for increasing the shear strength of pre-formed element comprising the step of applying at least one layer of fluid curing material along the length of the element on and around the inside corner/joint and/or the outside corner/joint of the element.

Description

Strengthened pre-shaped isolation elements The present invention relates to building elements and in particular to strengthened isolation elements of expanded or extruded polystyrene for the building industry.

Expanded polystyrene, EPS and extruded polystyrene, XPS, is used commonly to form building block in the building industry. The material has high isolation capability, it is light and it is easily formed to be adapted to a wide variety of requirements. It is however a problem that the material brakes easily. This is specifically a problem if the material is used in pre-formed shapes, such as for example L-form and U-form. Such elements are used for example in cold locations experiencing periods with ground frost. There is thus a need for extra isolation in the base of the wall, not only offering isolation in the wall, but also in the floor adjacent to the wall. When adding concrete to make the floor inside a building where such L- or U-form elements defines the perimeter of the building, the concrete will push with considerable force on the vertical inner part of the elements, and the pushing force is proportional to the depth of the concrete layer. If the forces becomes too large the element will break, and this is a considerable problem since a breakage in the isolation will weaken the isolation capability of the wall. One example of this type of pre-shaped element is the Siroc<®>L-shaped element of Jackon AS.

A lot of care has to be put into the building process to avoid such damages.

A further drawback of the L- U- and other forms elements is that they are prone to be damaged in transport, and extreme care has to be exercised when transporting such elements.

It is an object of the invention to solve the technical problem stated above. Although the Siroc<®>L-shaped and U-shaped elements of Jackon AS is used in the examples of this document, it is an aim for the invention to solve the same objective problem for any type of EPS or XPS elements, or similar elements made of other isolation building material.

It is a further objective of the invention to provide a method for enforcing EPS and XPS and the like elements used for other purposes than building. Pre-formed elements for protection of shipped goods is one example, Box forms intended for carrying heavy goods is another example. Although the examples in this description highlight the use of the invention in building elements, it should be understood that the invention can be used to enforce elements made for other intended use.

The invention is directed to the manufacture of improved performance building materials, specifically building materials of materials such as EPS and XPS and the like.

The present invention comprises a method for enforcing a building element made of EPS, XPS or similar material. It is further an object for the invention to provide a simple and low resource demanding method for achieving the increased strength in such building elements.

It is further an object of the invention to allow usage of lower density EPS and XPS or the like elements due to the enforcement added to the elements as defined by the present invention.

The invention is described with reference to the accompanying figures of which: Fig. 1 is an illustration of a standard L-formed building element.

Fig. 2A - 2C illustrates how L- and U-formed building elements are used forming the base of a wall in a building placed on ground and that must be prepared for ground frost.

Fig. 3 is a further illustration of L-formed building elements, wall and corner, comprising an additional outer wall layer.

Fig. 4 is an illustration of a building process laying out the base elements for a building.

Fig. 5 shows an embodiment of the invention showing the L-formed element with a glue/polymer layer in the inside joint area.

Fig. 6 A, 6B and 6C shows an embodiment of the invention showing the L-formed element with a glue layer and enforcement in the inside joint area, and a glue layer and optional enforcement on the outside joint area.

Fig. 7 shows a test jig for testing the breaking point of an L-formed element.

Fig. 8 shows a picture of an L-element with glue enforcement on half of the joint length.

Fig. 9 shows a broken L-form element after being tested for strength.

In the description and claims of the present invention the following words and phrases are used to comprise not only the general meaning of the same, but also: EPS, XPS: Expanded polystyrene, EPS and extruded polystyrene, XPS, is used in this document, but shall also comprise other similar building materials typically used in forming building elements with high isolation capacity; examples are Polyisocyanurate Insulation Materials, and Polyurethane Insulation Materials.

The invention will now be described in more detail. Reference numbers referring to the same in the figures are included to make the understanding of the invention more readable. The protection scope of the invention is defined by the associated claims.

Fiberglass: Fiberglass is used as an armoring component, and it shall be understood that it in the present application shall comprise other typical reinforcement fibers/fabrics, such as for example carbon fibers.

Glue: Glue shall mean any type of glue, polymer, polyester resin, epoxy, vinylester, thermoplastic or other, applied in layer or mixed with a fiberglass component, comprising the ability to either harden and provide a solid enforcement of the material it is applied to by its own, or to fix and/or mix with a strip or spray of enforcement/armoring material when it is applied to surface (joint).

L- or U-formed element: L- or U-formed element is used as example shapes of the building elements in this application, but it shall also comprise other forms offering an inside corner or joint exposable to shear forces when used or transported. The forms may be produced from several parts forming joints when assembled in the final form, or they may be extruded/expanded into the final form in one piece.

Figure 1 -4 illustrates how an L-formed 1 and U-formed 8 building element is used when forming the base of a wall 7 or perimeter of a floor 6. Typically the EPS, XPS element is used when building in areas experiencing frost in the ground 10, examples are the Nordic countries where the winters are very cold, and the ground freezes solid in the top soil level 11, typically the upper 0 - 1 m layer of the ground.

The L-/U-element having a horizontal leg 2 forming the basis for a layer of concrete 6, and a vertical leg 3 having an inside surface facing towards and coming in contact with the concrete 6 forming the floor inside the building. These elements are similar for both the L-element and the U-element. Figure 3 shows also a corner element 9 of the L-formed element. The illustrated elements may also comprise an optional outer surface layer 4, the outer surface layer 4 may be one or more of a concrete compound material, material forming a basis for applying a further layer or attaching further elements, material for temperature and/or damp isolation, or material and/or structure for the purpose of exhibiting a visual design.

Figure 4 shows how a U-element is used to form the perimeter of a building before the concrete is filled inside the building perimeter to form the floor.

When force 53 are applied to the element 1, working in the direction towards the second vertical leg 3, such as when filling concrete into the building perimeter defined by the elements 1, the force 53 may cause the vertical leg to break from the rest of the element. This is simulated in the test jig shown in figure 7, and at a certain load level is reached caused by the force 53, shown in figure 9.

In one embodiment of the invention the L-formed element joint 5 is enforced with a glue layer 50 strip. The glue layer strip 50 is prearranged to the element in production or pre-shipping to the builder, and the strip have a width on each leg between 0,1 and 10 cm wide, and typically between 2 and 5 cm wide. Typical glue/polymer thickness is 0,5 - 1,5 mm.

The glue layer may be applied by a sprayer, a brush or similar. The strength, hardness and thickness of the glue layer will be factors that influence on the added strength the glue will give the element. The glue layer may be applied more than once. Having different specification in the glue may give a sandwich layered structure.

A further embodiment will include enforcing the joint 5 and the glue 50 with a strip 60 of fiberglass or similar armoring material. This may increase the strength further. In one embodiment the armoring material may be composed of enforcement corner strip 61 formed to match the angle of the joint 5, or in the form of a flexiangle corner strip 61 to be flexibly adaptable to different joint 5 angles. In the latter case the corner strip is either arranged in the still wet glue after application but before curing/hardening, or a separate glue layer is applied for fixing the corner strip 61. The list may in an even further embodiment of the invention be attached to the joint 5 without pre-application of a glue layer. The glue may be applied together with the corner strip 61. One option is to provide a corner strip 61 with a two sided tape on the side that is to be attached to the joint 5. It is also possible to apply the armoring through a spraying operation. Typically a spray gun 64 is used to spray fibers such as fiberglass, optionally mixed with a glue component. When glue is comprised in the sprayed mix, the initial application of a strip of glue may be omitted. If dry fiberglass shreds are the only component in the spray, the fiberglass should be sprayed on to the strip of glue 50 whilst the glue is still wet to obtain best hardening process of the glue-fiberglass mixture.

Figure 6A - 6C further show an optional enforcement 62 of the outside joint between the vertical and horizontal arm of the L-shaped element. This enforcement is either a glue layer strip 62 or a glue layer strip 62 with an enforcement armoring material 63 as described in above for the inside joint 5, such as a fiberglass strip or a more rigid flat strip 63. Although such outside enforcement have little or no impact on the solidity of the element when concrete is applied to a floor inside the perimeter defined by one or more elements, it will improve the strength of the element due to damages likely to incur in transport and/or handling before use on the building site. Bending forces during transport and handling have a tendency to cause braking damages in the outside joints of the legs of the element. The enforcement strip 62, 63 improves the strength and reduces brakeage considerably. An enforcement material strip 63 may be provided with pre-attached two-way tape for attachment/gluing to the element in the outside joint area. In a similar manner to the inside joint, it is possible to apply armoring in a way of using a spray gun 63 to apply for example dry fiberglass, a wet mixture of glue and fiberglass, or other armoring components and/or hardener.

The strips 61, 63 discussed above may be of a stiff plastic compound or any other solid or semi-solid material with properties allowing it to be fixedly attached to the elements by glue/polymer/tape.

Image available on "Original document" Image available on "Original document" A preliminary test has been performed in a test rig as shown in figure 7, where the elements were fastened to the ground at the horizontal leg. A measurable force was pulling on the vertical leg, simulating the force a concrete layer will represent when filled on the floor.

The test was performed with to different types of Siroc<®>L-shaped element of Jackon AS, densities/qualities (kPa/kPa) 100/200 and 200/200. The pulling force applied in each test was increased until the element in the test jig broke in the joint area of the element. 3 different teat cases for each product were performed. One where the element was unmodified, one where glue was sprayed in the joint 5 area which was allowed to cure and harden, and one where glue was sprayed in the joint, and a strip of fiberglass was applied on the still wet glue strip. This resulted in a reinforced glue layer area along the joint 5.

When the test result was assessed, as seen in table 1, it was clear that a simple pre-treatment of sprayed glue would increase the strength of the element with more than 50 %. Variations were seen due to the difficulties in spraying a uniform layer of glue. It is foreseen that the optimization of application and thickness of the glue strip it will be possible to provide elements with at least a consistent increased strength of more than 70%, and if using reinforcement/armoring, more than 100% improved strength.

Due to the increased strength of the elements when being enforced according to the present invention, the builder may choose a lighter element for a specific concrete type floor.

The sprayed glue and the glue and armoring (fiberglass) spread the bending forces over a larger area, as well as increasing the strength, of the elements joint and the brakeage came typically not in the joint of the two legs of the element when the pulling force was applied.

The glue may be sprayed by a robot spraying machine, and the glue may be of a type hot-melt glue, to achieve consistent layer thickness and quick curing/hardening. It is within the scope of the invention to use other types of glue and application methods.

To further strengthen the joint the glue 50 can be mixed with reinforcement material such as fiberglass. It may also be possible to apply the glue and reinforcement material 60 in two operations, either manually, automatically or semi-automatically.

In the figures the Siroc<®>L-shaped element of Jackon AS is shown. This element is produced by two elements being glued together in the lower end. It is within the scope of the invention to use the method on other types of elements, also such elements that are formed out of one piece of EPS, or XPS block. These elements do not have a joint area, but the same effect of the invention will be achieved when glue and /or reinforcement material is applied in the area where the horizontal and the vertical leg meet.

The U-element sows several inner joint areas, the joint area 5 towards the concrete floor, and also two joint areas 40, 41 towards the concrete forming the bottom part of the wall. In some instances it will be advantageous to use the invention method on these two joint areas 40, 41 towards the concrete forming the bottom part of the wall as well.

In order to minimize the thickness of EPS, XPS material in carriers, boxes and containers for carrying goods, such as groceries and food, the carriers and the like may be enforced by using the present invention to reinforce them.

The invention can also be described as a first method embodiment for increasing the shear strength of preformed element 1, 8, the method comprising the step of applying at least one layer of fluid curing material 50, 51, 52, 62 along the length of the element 1, 8 on and around the inside corner/joint 5 and/or the outside corner/joint 12 of the element 1, 8.

A second method embodiment according to the first method embodiment, wherein the method further comprising the step of applying a solid material 60,61, 63, 64 along the length of the element 1, 8 on and around the inside corner/joint 5 and/or the outside corner/joint 12 of the element 1, 8.

A third method embodiment according to the first method embodiment, wherein the fluid curing material 50, 51, 52, 62 also comprise components of a solid material 64.

A fourth method embodiment according to any of the first to third method embodiment, wherein the method further comprise the step of let the curing material 50, 51, 52, 62 harden.

A fifth method embodiment according to any of the first to fourth method embodiment, wherein the fluid curing material 50, 51, 52, 62 is glue.

A sixth method embodiment according to any of the first to fifth method embodiment, wherein the solid material is made of stiff plastic A seventh method embodiment according to any of the first to sixth method embodiment, wherein the fluid curing material 50, 51, 52, 62 is hot melt glue or a polymer compound.

An eight method embodiment according to any of the first to seventh method embodiment, wherein the preformed element is an L- or U-formed element 1, 8, and is further a building materiel of EPS or XPS or the like material.

A ninth method embodiment according to any of the first to eight method embodiment, wherein the preformed element 1, 8 is elements in a carrier, container or box.

A tenth method embodiment according to any of the first to ninth method embodiment, wherein the application of the fluid curing material 50, 51, 52 is performed by a robot spraying machine.

An eleventh method embodiment according to any of the first to tenth method embodiment, wherein the application of the at least one layer of reinforcement 60, 61, 63, 64 is performed by a robot or robot spraying machine.

The invention can also be described as a first device embodiment of a pre-formed element 1, 8, wherein the element comprising at least one layer of fluid curing material 50, 51, 52, 62 along the length of the element 1, 8 on and around the inside corner/joint 5 and/or the outside corner/joint 12 of the element 1, 8, for enforcement of the corner/joint 5, 12 when the curing material 50, 51, 52, 62 has hardened.

A second device embodiment of the pre-formed element 1, 8 according to the first device embodiment, further comprising a solid material 60,61, 63, 64 along the length of the element 1, 8 on and around the inside corner/joint 5 and/or the outside corner/joint 12 of the element 1, 8.

A third device embodiment of the pre-formed element 1, 8 according to the first device embodiment, wherein the fluid curing material 50, 51, 52, 62 also comprise components of a solid material 64.

A fourth device embodiment of the pre-formed element 1, 8 according to any of the first to third device embodiment, wherein the fluid curing material 50, 51, 52, 62 is glue.

A fifth device embodiment of the pre-formed element 1, 8 according to any of the first to fourth device embodiment, wherein the solid material is made of stiff plastic A sixth device embodiment of the pre-formed element 1, 8 according to any of the first to fifth device embodiment, wherein the fluid curing material 50, 51, 52, 62 is hot melt glue or a polymer compound.

A seventh device embodiment of the pre-formed element 1, 8 according to any of the first to sixth device embodiment, wherein the pre-formed element is an L- or U-formed element 1, 8, and the element is further a is a building materiel of EPS or XPS or the like material.

An eight device embodiment of the pre-formed element 1, 8 according to any of the first to seventh device embodiment, wherein the pre-formed element is an L- or U-formed element 1, 8 and the element is elements combined to form a carrier, container or box.

Claims

1. Claims. 1. Method for increasing the shear strength of a pre-formed element (1, 8), wherein the method comprises the following steps: applying at least one layer of fluid curing material (50, 51, 52, 62) along the length of the element (1, 8) on and around the inside corner/joint (5) and/or the outside corner/joint (12) of the element (1, 8).

2. Method according to claim 1, wherein the method further comprise the step of applying a solid material (60,61, 63, 64) along the length of the element (1, 8) on and around the inside corner/joint (5) and/or the outside corner/joint (12) of the element (1, 8).

3. Method according to claim 1, wherein the fluid curing material (50, 51, 52, 62) also comprise components of a solid material (64).

4. Method according to any of claim 1 to 3, wherein the method further comprise the step of let the curing material (50, 51, 52, 62) harden.

5. Method according to any of the previous claims, wherein the fluid curing material (50, 51, 52, 62) is glue.

6. Method according to claim 1, wherein the solid material is made of stiff plastic

7. Method according to any of the previous claims, wherein the fluid curing material (50, 51, 52, 62) is hot melt glue or a polymer compound.

8. Method according to any of the previous claims, wherein the pre-formed element is an L- or U-formed element (1, 8), and is further a building materiel of EPS or XPS or the like material.

9. Method according to any of the previous claims, wherein the pre-formed element (1, 8) is elements in a carrier, container or box.

10. Method according to any of the previous claims, wherein the application of the fluid curing material (50, 51, 52) is performed by a robot spraying machine.

11. Method according to any of the previous claims, wherein the application of the at least one layer of reinforcement (60, 61, 63, 64) is performed by a robot or robot spraying machine.

12. Pre-formed element (1, 8), wherein the element comprising at least one layer of fluid curing material (50, 51, 52, 62) along the length of the element (1, 8) on and around the inside corner/joint (5) and/or the outside corner/joint (12) of the element (1, 8), for enforcement of the joint (5, 12) when the curing material (50, 51, 52, 62) has hardened.

13. Element according to claim 12, further comprising a solid material (60,61, 63, 64) along the length of the element (1, 8) on and around the inside corner/joint (5) and/or the outside corner/joint (12) of the element (1, 8).

14. Element according to claim 12, wherein the fluid curing material (50, 51, 52, 62) also comprise components of a solid material (64).

15. Element according to any of the previous claims 12 to 14, wherein the fluid curing material (50, 51, 52, 62) is glue.

16. Element according to claim 12 or 15, wherein the solid material is made of stiff plastic

17. Element according to any of the previous claims 12 to 16, wherein the fluid curing material (50, 51, 52, 62) is hot melt glue or a polymer compound.

18. Element according to any of the previous claims 12 to 17, wherein the pre-formed element is an L- or U-formed element (1, 8), and the element is further a building materiel of EPS or XPS or the like material.

19. Element according to any of the previous claims 12 to 18, wherein the pre-formed element is an L- or U-formed element (1, 8) and the element is elements combined to form a carrier, container or box.