SK500722020U1 - Sandwich masonry block - Google Patents

Abstract

The sandwich masonry block has two horizontal edges (3) adapted to be stacked in rows and two vertical edges (4) adapted to accommodate adjacent masonry blocks. It has a core (1) made of insulating material (8), which has a layer of plasterboard (2) connected on both opposite outer sides. The core (1) is adapted at the lower and upper horizontal edges (3) to transmit gravity in contact with the core (1) of the adjacent sandwich masonry block. The core (1) is also adapted to be connected to the core (1) of an adjacent sandwich masonry block by gluing with a bonding compound (7), preferably with polyurethane foam or with a gypsum and / or cement-based adhesive. The plasterboard (2) has obliquely chamfered edges (5) around the perimeter. In a preferred embodiment, the core protrudes over the edges of the plasterboard (2) and at the opposite edge the edges of the plasterboard (2) protrude over the edge of the core (1). The block directly includes the resulting smooth surface, masonry is very intuitive and the blocks are easy to handle.

Description

S K 50072-2020 U1

Technical field

The technical solution relates to a wall masonry block, in particular for the masonry of load-bearing or non-load-bearing interior walls, where the masonry block has smooth external surfaces formed by a layer of plasterboard. The masonry block allows for quick construction and can be bonded together with polyurethane foam and / or wet building material with cement and / or gypsum.

Prior art

Various masonry elements and blocks are known, from which the wall is gradually built. Subsequently, the wall must be plastered or otherwise provided with a smooth and level surface on one or both sides. Masonry is a wet process in which moisture is introduced into a building structure. Masonry using conventional materials, such as fired brick or concrete blocks, is manually difficult and cutting such blocks is time consuming.

Dry wall exhibition processes are also known, in which a load-bearing structure is formed, for example from galvanized sheet metal profiles, and a layer of plasterboard is attached to the load-bearing structure, which forms the final surface layer. The dry construction process is advantageous for its speed and for limiting the amount of water introduced into the building structure. The disadvantage of dry construction is the need for sufficient experience and the appropriate tools to create the supporting structure. Before closing the supporting structure on both sides, thermal insulation, usually made of soft insulating wool, is inserted inside it, which again requires measuring and cutting the material to measure.

WO2008124430A1 discloses a planar insulation panel which is provided with fibrous plasterboards on both outer surfaces. The inside of the panel is made of expanded polystyrene. This solution still requires the creation of a supporting structure. GB2493197A discloses a wall panel with fiberboard, between which there is stone wool insulation. The use of this wall panel requires not only the construction of the supporting structure, but also the finishing of the surface in the form of a thin layer of plaster or wallpaper.

The building panel according to US2003033774A1 has a sandwich structure and comprises a gypsum board on at least one side of the insulating core. The building panel is designed as a large area, where its dimensions correspond to the relevant wall or ceiling of the building. Such a solution requires the production of custom-made building panels and mechanized handling of the panels instead of installation.

A new technical solution is in demand and is not known, which will combine the advantages of classic masonry and dry construction. The new technical solution is intended to enable flexible construction of the wall using blocks, while at the same time an external surface with a final finish is to be obtained in one step.

The essence of the technical solution

These shortcomings are substantially eliminated by a sandwich masonry block which is intended for masonry in at least two layers one on top of the other and which has two horizontal edges adapted to be stacked in rows and two vertical edges adapted to accommodate adjacent masonry blocks in the respective row. masonry block is greater than the thickness of the masonry block according to this technical solution, the essence of which consists in that it comprises a core with insulating material, having a layer of plasterboard connected on both opposite outer sides and the core being adapted on the lower horizontal edge and on the upper horizontal edge transmission of gravity forces.

An essential feature of the presented technical solution is the direct connection of the insulating material with the plasterboard on both outer sides of the masonry block. In this document, the outer sides of the block are the sides which, after masonry, form the surface of the wall. The block has two outer sides (outer surfaces), two horizontal edges intended mainly for laying on top of each other and two vertical edges intended mainly for connecting adjacent blocks in the same row.

The adaptation of the lower and upper horizontal edges to the transmission of gravity forces is such a shape and dimensional arrangement that, after masonry, a contact is made with the core of the adjacent sandwich masonry block. In contact with this, the bonding compound which will bond the blocks will be glued to the solid wall at least on a part of the contact surface.

Both gypsum board and insulation material are considered to be elements without a load-bearing function, but it has been shown that a sufficiently rigid and durable sandwich construction element is formed when the core of insulation material with gypsum board is printed on. The core of insulating material is made at the lower and upper edge so that the tensile force from the masonry blocks is transmitted through the core of insulating material. Although the allowable pressure will be relatively low for the insulation material used, the large cross-sectional area of the core of insulation material will ensure

With K 50072-2020 U1 sufficiently high load-bearing capacity of the finished wall. In the case of non-load-bearing walls which bear only their own weight and possibly the weight of suspended objects, a sandwich masonry block is an advantageous technical solution, even at relatively small thicknesses, where the core consists of only one layer of insulating material.

The present basic principle of surface bonding of an insulating material and a layer of gypsum board can advantageously also be used in the solution of a load-bearing wall in which the number of alternating layers of gypsum board and layers of insulating material is repeated. A sandwich masonry block for load-bearing walls will comprise two outer layers of plasterboard and at least one layer of plasterboard in a core with insulating material. Such a sandwich masonry block can be made by gradually gluing a layer of plasterboard with a layer of insulating material, for example to the assembly: plasterboard - board insulation material - plasterboard - a plate of insulation material - plasterboard or to the assembly: plasterboard - a plate of insulation material - plasterboard-a plate of insulation material - plasterboard-a plate of insulation material - plasterboard.

By increasing the number of layers of plasterboard inside, the bending and compressive strength of the sandwich masonry block increases, while in the perpendicular direction a high thermal resistance is maintained without thermal bridges in the horizontal direction. Conventionally, the load-bearing sandwich masonry block according to this technical solution may comprise two inner layers of plasterboard wrapped together with three layers of insulating material, the sandwich masonry block having two outer layers of plasterboard on the outer sides.

The masonry sandwich blocks for load-bearing walls can be laid and masonry in two rows next to one another, which increases the overall thickness of the masonry wall. When masonry in two rows, the second row can be established in the corners with a distance in the thickness of one row, which creates a fold in the corner that reduces the heat transfer in the plasterboard layer.

Combining several repeating layers of plasterboard with layers of insulating material into one compact unit significantly improves the mechanical properties to such an extent that the sandwich masonry block can be used as a lintel. In this embodiment, the sandwich masonry block will have a length that exceeds three times the height and will include at least one internally placed layer of plasterboard. Depending on the length of the lintel and the required load, the number of internally placed layers of plasterboard will be designed, and this number must not match the number of layers of plasterboard in the adjacent blocks.

The sandwich masonry block according to this technical solution can have relatively large external dimensions, since the basis weight of both the plasterboard and the insulating material is low. Concrete or aerated concrete blocks have a higher specific gravity and, for handling reasons, the dimensions of these blocks are relatively small, which leads to the formation of a larger number of connecting lines. The sandwich masonry block according to this technical solution can be made with relatively large external dimensions at different thicknesses, while maintaining easy handling and achieving a masonry speed.

The core of insulating material is well adapted for gluing with available construction adhesives. When masonry sandwich masonry blocks, a polyurethane adhesive can be used in a box that cures with air humidity. In this case, the masonry is essentially a dry process without the addition of water and moisture to the masonry wall, and the resulting structure has the required strength several hours after the masonry of the last block. The advantage of such a procedure is also the fact that the application of PUR glue from cans is a common skill of construction workers.

The sandwich masonry block can be easily cut with hand tools or even by machine, without creating unnecessary waste. Sandwich masonry block has good thermal and sound insulation properties.

The core of the sandwich masonry block can be made of a thermoplastic polymer, in particular of expanded expanded polystyrene and / or extruded expanded polystyrene. The core of the sandwich masonry block can also be made of insulating wool, for example mineral wool, which consists of inorganic fibers of natural or synthetic origin, preferably this insulating material is of a harder consistency, for example in the case of a sleek insulation. The gypsum board will be flat-attached to the core of insulating material, preferably by means of an adhesive, for example a mounting polyurethane adhesive. In the case of mass production, the plasterboard and / or the core of insulating material can be formed directly during the process so that they are interconnected.

The printed circuit board and the core of insulating material will preferably be provided by gluing, for example with low-expansion polyurethane adhesive foam. The layer of gypsum board will preferably consist of a conventional gypsum board or an impregnated gypsum board, for example with a thickness of 12.5 mm. Fire-resistant gypsum board can also be used to increase the fire resistance. The design of the fire-retardant plasterboard combined with the mineral wool core has a high fire resistance, while there is no undesired heat transfer through the metal parts of the structure.

Since masonry with a sandwich masonry block according to this technical solution creates joints of the plasterboard layer at the edges of the block, it is advantageous if the plasterboard layer has an obliquely chamfered edge around the circumference, which allows fast bonding. At the same time, unlike the sealing of classically assembled plasterboard, it is not necessary to seal and grind the screw heads. Sealing joints me

With K 50072-2020 U1, the bricks are fast also due to the fact that the overall length of the joints is small with the relatively large dimensions of the sandwich masonry blocks.

The sandwich masonry block can be made so that the edges of the plasterboard are flush with the respective edge of the core of insulating material, or in a preferred arrangement these edges can be offset from each other so as to form a form lock for easy alignment and joining of adjacent blocks. For example, in one embodiment, the lower horizontal edge of the core of insulating material protrudes beyond the edges of the plasterboard, and conversely, at the upper horizontal edge, the edges of the adroc cardboard protrude beyond the edge of the core of insulating material. This creates a tongue-and-groove shape lock. Vertical edges can be adjusted similarly. The protruding edge simply cuts off when the first row is laid.

In a preferred embodiment, at least one groove can be formed in the core of insulating material for accommodating the reinforcement. As it turned out during the invention of the technical solution in question, the interior wall has sufficient rigidity and strength even at a block thickness of 75 mm. The stiffness, in particular the bending stiffness of longer walls, can be increased by laying horizontal reinforcements, while conventional steel ribbed bars used as reinforcement in reinforced concrete can be used. One reinforcement is placed in one horizontal groove in the center line of the insulation core or two reinforcements are inserted in the horizontal grooves which are formed in the insulation core near the connection of the insulation core with the plasterboard layers. In another embodiment, the grooves on the reinforcement need not be formed as separate depressions in the core of insulating material, but the protruding lower horizontal edge of the core of insulating material may be less than the depth of the groove at the opposite upper horizontal edge and the difference of these dimensions will correspond at least to the thickness of the reinforcement used.

When using overlapping edges of the core of insulating material in the form of a "tongue-and-groove" shape lock, it is advantageous if the sandwich masonry block is laid so that the horizontal edge with protruding layers of plasterboard is placed at the top, thus creating a tray along the entire wall line. The reinforcement is simply placed in this tray and can be foamed with polyurethane assembly foam or it can be poured with gypsum mortar or a similar fast-setting construction mixture.

The dimensions of sandwich masonry blocks can be derived from the dimensions of gypsum plasterboards so that no waste is generated with the standard type dimensions of gypsum plasterboards. For example, a plasterboard board with a length of 2,000 mm will be divided into three parts, a sandwich masonry block will have boards with a size of about 666.5 mm. Such a procedure will make it possible to produce sandwich masonry blocks with simple technological equipment, where gypsum plasterboards and insulating material with different thicknesses enter the production.

The core of insulating material can also be provided with grooves or channels for the routing of installation wiring, in particular for the routing of electrical cables. In a preferred embodiment, sandwich masonry blocks can be produced with recessed installation boxes which open into the openings in the plasterboard.

The advantage of the presented technical solution is a very fast construction of load-bearing and non-load-bearing walls, where the masonry block directly includes the resulting smooth surface thanks to plasterboard. which forms part of a sandwich block. The masonry is very intuitive and the handling of blocks and lintels is easy. The resulting wall has excellent mechanical and visual properties.

Overview of figures in the drawings

The technical solution is explained in more detail with the help of Figures 1 to 8. The illustrated scale of individual elements, the displayed dimensional ratios are only an example and should not be explained as features limiting the scope of protection.

Figure 1 is a perspective view of an interior sandwich masonry block having tongue-and-groove edges formed.

Figure 2 shows a view of sandwich masonry blocks laid on top of each other in three rows, showing the still unsealed chamfers of the plasterboard edges. The picture also shows the folding of sandwich masonry blocks in individual rows. The dashed line shows the protruding edge of the insulation material that forms the tongue-and-groove connection. In the horizontal gaps between the edges of the insulating material, a steel reinforcement is inserted, which is not shown in Figure 2 for clarity.

Figure 3 shows a cross-section of a sandwich masonry block with placed steel reinforcement in the form of ribbed steel bars.

Figure 4 shows a detailed view of a joint of sandwich masonry blocks stacked on top of each other, the steel reinforcement being encapsulated with gypsum mortar, which at the same time forms a joint.

Figure 5 shows an example of an interior wall with a door frame, where the dashed line shows the lines of individual sandwich masonry blocks. The lintel above the door consists of a sandwich masonry block with several layers of plasterboard, similar to a load-bearing wall.

Figure 6 shows a view of a simple embodiment of a sandwich masonry block with aligned edges of the core and plasterboard.

S K 50072-2020 U1

Figure 7 is a view of a sandwich masonry block in an embodiment for a load-bearing wall, where the sandwich masonry block has a total of four layers of plasterboard and three layers of insulating material. The arrows in the figure show the adjacent placement of two rows of sandwich masonry blocks in a single-wall wall. Subsequently, Figure 8 shows a plan view of the corner of the load-bearing wall with correctly placed sandwich wall blocks to reduce the heat transfer in the corner.

Examples of embodiments

Example 1

In this example according to Figures 1 and 5, the sandwich masonry block is formed by a core 1 of extruded polystyrene and two sheets of plasterboard 2. In this example, extruded polystyrene with a thickness of 100 mm with a permissible compressive load of up to 700 kPa is used.

Plasterboard boards 2 with a thickness of 12.5 mm are made of the classic dimension of a solid board with dimensions of 10200 mm x 20000 mm so that the solid board is cut into three equal parts. Said division in this example creates a dimension of 1,200 mm x 666 mm, which also corresponds to the dimension of the entire sandwich masonry block.

The core 1 has the dimensions 1,200 mm x 666 mm. Plasterboard 2 is glued to both outer sides of the core 1 so that on the lower horizontal edge 3 the core 1 protrudes over the edge of the plasterboard 2 by 10 mm. Conversely on the upper horizontal edge 3 the edges of the plasterboard 2 protrude over the edge of the core 1 by 10 mm. 2 and the core 1 at the vertical edges 4. This creates a tongue-and-groove locking connection around the entire circumference of the sandwich masonry block.

The total weight of the sandwich masonry block with the above dimensions does not exceed 15 kg, thanks to which it is easy to handle. With a core thickness of 1 mm 1, the yield strength reaches a value of up to 50 kN per meter of wall length, which is reliably sufficient mechanical strength.

All edges of the plasterboard 2 have obliquely chamfered edges 5 on the outside. The joints are ground with a common sealant used in dry construction.

In this example, the sandwich masonry block is glued to one another by means of a polyurethane assembly foam, which quickly achieves the strength required for laying the next layer. To brick a wall with a height of, for example, 2,500 mm, it is sufficient to build four rows of sandwich masonry blocks. The number and total length of the joints is therefore relatively small.

In Figure 5, the wall is masonry as a partition between two load-bearing walls, the entire partition having a low weight, not loading the ceiling slab on which it is masonry.

Example 2

In this example, the polystyrene foam core 1 according to Figures 2 to 5 is formed so that the lower edge of the core 1 does not abut directly on the upper edge of the core 1 of the adjacent block, but there is a gap of 10 mm between them, which forms a channel for laying reinforcement 6. for laying electrical cables. After laying the sandwich masonry blocks in one layer, two steel bars forming a reinforcement 6 are placed in the formed channel and the channel is filled with a gypsum-based bonding compound 7. Subsequently, another row of sandwich masonry blocks is placed in the still uncured gypsum bed. In one step, the reinforcement 6 is connected to the core 1 and also the cores 1 of the superimposed blocks are connected to each other.

Example 3

In this example of Figure 6, a sandwich masonry block has a simple construction without protruding edges and can be manufactured directly on site. When gluing the plasterboard 2 to the surface of the core 1 made of insulating material 8, a work table with a perpendicularly bounded stop in the corner is used, which serves as an aid to achieve a precise parallel position of the edges of the plasterboard 2 and the core 1 made of insulating material 8.

Example 4

In this example according to Figures 7 and 8, a sandwich masonry block is made for a circumferential load-bearing wall, the core 1 comprising three layers of insulating material 8, between which two inner layers of plasterboard 2 are glued.

In this example, the sandwich masonry block has a height of about 500 mm, a length of 1,012 mm and a thickness of about 195 mm, which is the sum of the thicknesses of 4 x 12 mm (plasterboard 2) and 3 x 50 mm (insulation material 8). The wall of two adjacent rows has a total thickness of about 396 mm.

S K 50072-2020 U1

Industrial applicability

Industrial applicability is obvious. According to this technical solution, it is possible to industrially and repeatedly produce and use sandwich masonry blocks for masonry walls, in particular peripheral load-bearing walls and interior non-load-bearing walls, partitions, partitions, walls and the like.

S K 50072-2020 U1

List of reference marks

- the core

- plasterboard

3 - horizontal edge

- vertical edge

- obliquely chamfered edge

- reinforcement

- bonding compound

8 - insulating material

Claims (20)

S K 50072-2020 U1 CLAIMS FOR PROTECTION A sandwich masonry block which is intended to be masonry in at least two layers on top of one another and which has two horizontal edges (3) adapted to be stacked in rows and two vertical edges (4) adapted to abut adjacent masonry blocks in a respective row , wherein the height of the masonry block is greater than the thickness of the masonry block, characterized in that it comprises a core (1) with insulating material (8), the core (1) having a layer of plasterboard (2) flatly connected on both opposite outer sides and the core (1) is adapted at the lower horizontal edge (3) and at the upper horizontal edge (3) to transmit gravity of contact with the core (1) of the adjacent sandwich masonry block. Kit according to claim 1, characterized in that the insulating material (8) in the core (1) is expanded polystyrene. Sandwich masonry block according to Claim 2, characterized in that the insulating material (8) in the core (1) is expanded polystyrene foam. Sandwich masonry block according to Claim 2, characterized in that the insulating material (8) in the core (1) is extruded polystyrene foam. Sandwich masonry block according to Claim 1, characterized in that the insulating material (8) in the core (1) is mineral wool with fused earthenware fibers. Sandwich masonry block according to any one of claims 1 to 5, characterized by mamamas and in that the layers of plasterboard (2) are connected to the insulating material (8) by gluing Sandwich masonry block according to Claim 6, characterized in that the adhesive is a low-expansion polyurethane foam. Sandwich masonry block according to any one of claims 1 to 7, characterized in that the core (1) is adapted to be connected to the core (1) of an adjacent sandwich masonry block by gluing with a bonding compound (7), preferably with polyurethane foam or with an adhesive based gypsum and / or cement. Sandwich masonry block according to any one of claims 1 to 8, characterized in that the plasterboard (2) has obliquely chamfered edges (5) around the circumference on the outside. Sandwich masonry block according to any one of claims 1 to 9, characterized in that it has a thickness of at least 50 mm, preferably at least 100 mm Sandwich masonry block according to any one of claims 1 to 10, characterized in that it comprises at least one layer of gypsum board (2) which is arranged inside the core (1), a layer connected to the inner layer of gypsum board (2) on both sides. insulating material (8). Sandwich masonry block according to any one of claims 1 to 11, characterized in that on one horizontal edge (3) the core (1) of insulating material (8) projects over the edges of the plasterboard (2) and on the opposite horizontal edge (3) the edges of the plasterboard (2) protrude over the edge of the core (1) of insulating material (8). Sandwich masonry block according to any one of claims 1 to 12, characterized in that on one vertical edge (4) the core (1) of insulating material (8) projects beyond the edges of the plasterboard (2) and on the opposite vertical edge (4) plasterboard (2) over the edge of the core (1) of insulating material (8). Sandwich masonry block according to any one of claims 1 to 13, characterized in that the overhang of the edges is in the range of 5 to 25 mm, preferably 10 mm Sandwich masonry block according to any one of claims 1 to 14, characterized in that at least one groove for accommodating the reinforcement (6) is formed in the core (1) of insulating material (8). Sandwich masonry block according to claim 12 or 15, characterized in that the projecting lower horizontal edge (3) of the core (1) of insulating material (8) is lower than the depth of the cavity at the opposite upper horizontal edge (3), the difference of these dimensions corresponds at least to the thickness of the reinforcement (6). Sandwich masonry block according to any one of claims 1 to 16, characterized in that the dimension of the gypsum board (2) is divided without the remainder derived from the change of the integral gypsum board (2). Sandwich masonry block according to claim 17, characterized in that the gypsum board (2) has one dimension identical to the width of the solid gypsum board (2) and the other dimension is a residual portion of the gypsum board (2) height, preferably the second dimension is one third of the height solid gypsum board (2). Sandwich masonry block according to one of Claims 1 to 18, characterized in that the core (1) is provided with grooves or channels for the routing of installation distributions, in particular for the routing of electrical cables. Sandwich masonry block according to any one of claims 1 to 19, characterized in that it comprises recessed installation boxes which open into the openings in the plasterboard (2). 5 drawings