US20090094928A1

US20090094928A1 - Spacer and building component for a wall structure and method and device

Info

Publication number: US20090094928A1
Application number: US11/979,781
Authority: US
Inventors: Kurt Hirsch
Original assignee: Individual
Current assignee: Hirsch Maschinenbau GmbH; GGB Global Green Built GmbH
Priority date: 2007-10-15
Filing date: 2007-11-08
Publication date: 2009-04-16
Also published as: ES2438273T3; AT10444U1; EP2209952A1; CA2702430A1; EP2209952B1; WO2009049336A1; SI2209952T1

Abstract

In a building component or shuttering body (2) for the production of a wall structure including to oppositely located and substantially parallel, plate-shaped elements (6, 7) connected by at least two spacers (1), wherein the free space between the plate-shaped elements (6, 7) is fillable with an, in particular, settable mass, e.g. concrete, it is provided that it comprises at least two spacers (1) of polystyrene, in particular expandable polystyrene of elevated density, as well as plate-shaped elements (6, 7) of polystyrene, in particular expandable polystyrene, so as to enable the production of a building component (2) in a simple and cost-effective manner.

Description

FIELD OF THE INVENTION

The present invention relates to a spacer or connection element for a building component or shuttering body for the production of a wall structure including two oppositely located and substantially parallel, plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete. The present invention, moreover, relates to such a building component or shuttering body for the production of a wall structure, a method and device for producing such a building component or shuttering body, and a wall structure produced in this manner.

PRIOR ART

In the context of the production of wall structures, so-called insulated concrete forming systems are, for instance, known, in which building components or shuttering bodies comprising substantially parallel, plate-shaped elements and spacers arranged therebetween are employed, wherein the free space between the plate-shaped elements is, for instance, fillable with concrete such that, after the concrete has set, the building components or shuttering bodies will remain there as a lost shuttering and, if produced of synthetic materials, will directly serve as wall insulation means. In this context, embodiments are, for instance, known, in which the spacers are made of metallic materials, polypropylene or similar plastics produced, for instance, by injection molding.
Those embodiments involve the drawback that the spacers and plate-shaped elements of synthetic material, which are directly used as wall insulation means after the completion of the wall structure, are, thus, comprised of different materials, which will create problems in the disposal of such components or shuttering bodies. Taking into account the different materials, also different methods for producing the spacers and the plate-shaped elements are, moreover, required, the spacers being mostly produced in a separate production plant and, after transportation to the production plant of the plate-shaped elements, being used to form the desired building components or shuttering bodies. Furthermore, the spacers, which are usually made of synthetic materials by injection molding, are extremely expensive such that, in the main, comparatively high production costs will occur for such building components or shuttering bodies. Besides, such known building components, due to the different materials employed, are prone to damage in the regions of embedment of the spacers in the plate-shaped elements, since a reliable connection between the different materials of spacers and plate-shaped elements is, as a rule, not or only insufficiently achievable.
When producing such building components or shuttering bodies, it must, moreover, be taken into account that the spacers or connection elements have comparatively small cross sections between the plate-shaped elements, since an excessive weakening of the wall structure to be produced is to be feared in the region of such spacers. Furthermore, spacers having large cross-sectional areas are not suitable for ensuring appropriate fire protection, since spacers made of synthetic materials may burn through in case of fire if provided with larger cross sections.
Additionally, it is to be taken into consideration that partially high forces will have to be taken up by the spacers both during the filling procedure of the curable or settable mass, e.g. concrete, and during the subsequent compaction and setting process such that the spacers will have to exhibit accordingly high mechanical strengths. As already indicated above, the use of different materials for the spacers and the plate-shaped elements entails the risk of damage and breaking-out occurring in the region of the embedment of the spacers in the plate-shaped elements on account of the absent or only insufficiently present connection of the different materials, so that the shuttering function to be provided during the filling procedure and the setting process will not be reliably fulfilled.

SUMMARY OF THE INVENTION

The present invention aims to further improve a spacer or connection element for a building component or shuttering body, such a building component or shuttering body for the production of a wall structure as well as a method and device for producing such a building component or shuttering body, to the effect that the above-mentioned prior art drawbacks will be avoided while providing, in particular, in a simple and reliable manner, a spacer or connection element as well as a building component or shuttering body for the production of a wall structure, which exhibit the strength required for the production of a wall structure and are also able to meet other demands. In addition, it is aimed at providing a spacer or connection element as well as a building component or shuttering body, which can be made available at low production costs.
To solve these objects, a spacer or connection element of the initially defined kind is essentially characterized in that the spacer is made of polystyrene, in particular expandable polystyrene, of elevated density. Due to the fact that the spacer according to the invention is made of polystyrene, in particular expandable or foamed polystyrene (EPS) of elevated density, it is ensured that the mechanical strength required for the production of a building component or shuttering body will also be provided by a spacer made of polystyrene and, in particular, expandable polystyrene. By using a spacer or connection element of polystyrene and, in particular, expandable polystyrene, it is feasible to provide an accordingly cost-effective spacer which can be produced by molds or forms that are simpler and less expensive, especially in view of injection molding techniques.
Furthermore, as will be explained in more detail below, also the plate-shaped elements additionally provided for the production of the building component or shuttering body are, for instance, preferably likewise made of polystyrene and, in particular, expandable polystyrene such that, in the main, a complete building component or shuttering body can be produced of a uniform or identical material in a single production plant, thus enabling the plants required for the production of such a completed building component or shuttering body to be made available at reduced costs.
In addition, as will be explained in detail below, also an accordingly enhanced connection between the spacer or connection element and the plate-shaped elements will be provided by the production of the building component or shuttering body according to the invention and, in particular, by using a uniform material.
In order to obtain a suitable mechanical strength of the spacer even when using an expandable polystyrene, it is proposed according to a preferred embodiment that the density of the expandable polystyrene of the spacer is selected to range between 50 and 250 g/l and, in particular, from about 70 to 100 g/l. By using such an expandable polystyrene of elevated density in the indicated density ranges, it will be ensured that the forces occurring during a subsequent filling and setting process in the production of a wall structure using the so-called insulated concrete forming system will be taken up safely. When using expandable polystyrene with the elevated density indicated, it is, moreover, safeguarded that, after filling, spacers having accordingly small dimensions or cross sections will do to overcome, by accordingly simple means, the prior art problems mentioned in the beginning, particularly in regard to an enhanced fire protection and the provision of an impenetrable element, especially in the longitudinal direction of the spacer, on account of the small thickness to be achievable. Such securement against penetration of the spacer in the longitudinal direction is, for instance, important in areas of elevated dangers or risks with a view to providing the required bullet-proofness.
In order to obtain the desired strength characteristics and to provide a proper connection with the plate-shaped elements or embeddings in the latter, it is proposed according to a further preferred embodiment that the spacer is comprised of a planar element designed with an increased thickness in its end regions relative to the region located therebetween, said end regions being receivable in the plate-shaped elements of the building component. By providing a substantially central, planar or bar-shaped element, the forces to be taken up will be distributed over accordingly increased cross sections, whereby it is, moreover, feasible, on account of the end regions having increased thicknesses or dimensions substantially normally to the planar element, to ensure the reliable embedding or anchorage in the plate-shaped elements in the subsequent production of a building component or shuttering body.
In regard to providing an applicability as universal as possible, it is proposed according to a further preferred embodiment that the spacer, in a cross section, is substantially double-T-shaped with the T-like ends being receivable in the plate-shaped elements. Such a double-T- or I-shape causes the necessary forces to be reliably distributed over the planar, central or bar region, while the T-shaped ends are receivable in the plate-shaped elements or connectable with the plate-shaped elements over accordingly increased cross sections.
To further promote the subsequent connection with the plate-shaped element, it is proposed according to a further preferred embodiment that the spacer is designed to comprise reinforcements in its end regions, between the planar region and the end regions. Such reinforcements may be formed by connections between the substantially central, planar elements and the consecutively arranged T-shaped end regions.
To further increase the mechanical strength, it is proposed according to a further preferred embodiment that the spacer is reinforced by reinforcing elements. By using such additional reinforcing elements embedded in the spacer, accordingly enhanced mechanical strengths will be provided. Alternatively, when providing appropriate reinforcing elements, small material cross-sections for the spacers will do so as to not only meet the demands in respect to a small clear cross-section for an enhanced fire protection and bulletproofness, but also allow for the respective savings of material for the spacers.
An optionally desired reinforcement of the spacer will be obtained by embedding or incorporating different reinforcing elements, wherein it is, for instance, proposed in this connection that the reinforcing elements are comprised of loose, optionally hydrophilized, fibers embedded in the spacer. Such fibers can be provided in a great number of different embodiments as a function of the desired, in particular mechanical, properties to be achieved and also with a view to providing a simple connection with the material of the spacer, wherein such fibers may, for instance, have lengths ranging from 3 to 10 mm. Alternatively or additionally, it may be provided that the reinforcements are comprised of sieve-like or grid-like or net-shaped reinforcements or rods, which are embedded in the spacer, as in correspondence with a further preferred embodiment of the spacer according to the invention.
In order to obtain enhanced, in particular mechanical, properties when using accordingly cost-effective and optionally low-weight reinforcements, it is, moreover, proposed in a preferred manner that the reinforcements are made of metallic or synthetic material.
Since the spacers to be used for the production of building components or shuttering bodies extend substantially over the height of the respective plate-shaped element for providing a desired connection, a comparatively large amount of material is required for the production of the spacers, in particular for building components or shuttering bodies having larger dimensions. In order to reduce the material to be employed, it may, therefore, be provided that the spacer is designed to include at least one recess, depression or breakthrough extending substantially normally to its direction of extension, as in correspondence with a further preferred embodiment of the spacer according to the invention. Such recesses or depressions or breakthroughs, thus, allow for material savings with a view to enabling a cost-effective production of the spacer and, hence, of the building component or shuttering body to be produced. In addition, such depressions or recesses may, in particular, be used if provided in marginal or edge regions of the central, planar element or region for arranging and fixing or positioning armoring or reinforcing elements to be optionally additionally received in the wall structure to be produced.
With breakthroughs or recesses formed in the central, planar region, when subsequently filling in a settable mass, said mass, e.g. concrete, will also enter the breakthroughs, so that such breakthroughs will not only ensure the respective saving of material in the production of the spacers, but also provide a connection between the individual chambers or subregions of a building component or shuttering body, between the individual spacers. Moreover, thermal bridges and cold bridges will be avoided in the wall structure to be produced.
By arranging breakthroughs or recesses particularly in the planar or central region, it may, moreover, be ensured that a clear or average cross section will be accordingly reduced or limited, which will, in particular, contribute to an enhanced fire prevention and bulletproofness, as already pointed out above. In this context, it is proposed according to a further preferred embodiment that the spacer, in its planar, central region or element, is formed with at least one breakthrough to prevent the spacer from being penetrated by a linear element in its planar region. By preventing a substantially linear penetration of the spacer in its planar region or element, it will, thus, be ensured that a penetration will be prevented even in the case of optionally larger cross-sections of the spacer. The entry of the settable material into appropriately provided breakthroughs or recesses will, moreover, ensure that direct penetration of the spacer will not be possible even at a bombardment.
In the context of preventing the spacer from being penetrated by a linear element, or in a longitudinal direction, it may, moreover, be provided that the spacer is curved or cranked, or formed with relatively offset subregions, particularly in its central region, as in correspondence with a further preferred embodiment of the spacer according to the invention. Such a curved or cranked design or arrangement of relatively offset subregions can likewise be produced using accordingly simple forms or molds and, after filling with a settable or curable material, will prevent the spacer from being penetrated in a direction corresponding with the central, planar region.
When using polystyrene and, in particular, expandable polystyrene of elevated density, spacers with accordingly reduced dimensions or accordingly reduced thicknesses will do to produce the spacers, wherein, in this connection, it is proposed according to a further preferred embodiment that the spacer has a thickness of less than 25 mm and, in particular, about 5 to 20 mm and, most preferred, 10 to 15 mm.
To solve the objects set out in the beginning, a building component or shuttering body for the production of a wall structure including two oppositely arranged and substantially parallel plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete, is essentially characterized in that the building component comprises at least two spacers according to the invention, or a preferred embodiment thereof, and the plate-shaped elements are made of polystyrene, in particular expandable polystyrene. It is, thus, feasible, by a simple configuration, to provide an accordingly resistant building component or shuttering body, to which end, as already pointed out above, simplified production plants will do by forming both the spacer and the plate-shaped elements of polystyrene, in particular expandable polystyrene. In this respect, it should not only to be borne in mind that the same material is used both for the spacer and for the plate-shaped elements, but that both the spacer and the plate-shaped elements can be produced by accordingly simpler forming methods requiring less expensive tools as opposed, for instance, to the more cost-intensive molds required for injection molding. As likewise already indicated above, by forming both the spacers and the plate-shaped elements of polystyrene, in particular expandable polystyrene, it is, moreover, ensured that, by embedding the spacers and, in particular, their end portions in the plate-shaped elements, a reliable connection with the material of the surrounding plate-shaped elements is provided, wherein, by the application of foaming methods when using expandable polystyrene, a connection like a weld or fusion will be realized between the plate-shaped elements and the end regions of the spacers. Such a joint or weld provides an accordingly high-strength connection between the individual elements or components, whereby the forces occurring during the filling procedure and/or setting process will be distributed in the plate-shaped elements over a wide area through said connection such that accordingly high forces will also be reliably taken up, without having to fear damage to the building components or shuttering bodies according to the invention, in particular in the region of the connection between the spacers and the plate-shaped elements. Besides, a building component according to the invention will be simpler and less expensive to dispose of, since it is not made of different materials requiring separate disposal as is, for instance, common in the prior art.
In order to achieve the desired strength properties of the building component or shuttering body according to the invention when using spacers of expandable polystyrene, it is provided according to a further preferred embodiment that the spacers are formed of an expandable polystyrene having an elevated density relative to the material of the plate-shaped elements.
To produce accordingly light-weight building components or shuttering elements, it is, moreover, proposed according to a further preferred embodiment that the density of the expandable polystyrene for the plate-shaped elements is selected to range between 10 and 50 g/l and, in particular, from about 20 to 30 g/l.
For the use of the building component according to the invention for the production of a wall structure that is simple to construct, it is, moreover, proposed that the plate-shaped elements, on their upper and lower boundary edges, are at least partially provided with profiles cooperating with complementary profiles of a further building component arranged thereabove or therebelow, as in correspondence with a further preferred embodiment of the building component according to the invention. In this context, it is proposed according to a further preferred embodiment that the profiles are formed by substantially regularly arranged projections and depressions.
As already mentioned above, such building components or shuttering bodies according to the invention are used in a so-called insulated concrete forming system, wherein the building components or shuttering bodies will serve as lost shutterings, which, taking into account the plate-shaped elements made of synthetic material and, in particular, expandable polystyrene, will impart appropriate insulation properties to the completed wall structure. In order to obtain desired and optionally different insulation properties as a function of use, it is proposed according to a further preferred embodiment that the plate-shaped elements have different thicknesses.
To solve the objects set out in the beginning, a method for producing a building component or shuttering body for the production of a wall structure including two oppositely arranged and substantially parallel plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is filled with an, in particular, settable mass, e.g. concrete, is essentially characterized by the steps of:
producing spacers of polystyrene, in particular expandable polystyrene; and
forming the plate-shaped elements of polystyrene, in particular expandable polystyrene, in a mold, wherein the spacers are connected with, or embedded in, the plate-shaped elements in their end regions.
It is, thus, feasible to produce a building component or shuttering body according to the invention by simple steps and in a joint production plant for providing and processing polystyrene and, in particular expandable polystyrene. It is, thus, for instance, feasible to produce the building component or shuttering body according to the invention for the production of a wall structure in a joint method, wherein the spacers are produced of polystyrene, in particular expandable polystyrene of elevated density, in a first method step, whereupon the plate-shaped elements are likewise produced of polystyrene, in particular expandable polystyrene, in a second method step, using, for instance, a joint mold in which polystyrenes, in particular expandable polystyrenes, of different densities are introduced into the subregions respectively provided for the spacers and the plate-shaped elements.
Alternatively, and optionally for the provision of simpler molds, it may be provided that the spacers of polystyrene, in particular expandable polystyrene, are produced in separate molds, as in correspondence with a preferred embodiment of the method according to the invention, such that polystyrenes, in particular expandable polystyrenes, of different densities are each introduced into a separate mold for the production of a spacer of elevated density according to the invention and the plate-shaped elements of lower density, respectively.
In particular, when producing the spacers in separate molds, the initially produced spacers are subsequently placed in a mold as a function of the plate-shaped elements, as in correspondence with a further preferred embodiment of the method according to the invention, wherein, by the subsequent production and, in particular, foaming of the plate-shaped elements, the latter are reliably and safely connected directly with the spacers in the end regions of the same.
In order to obtain accordingly high mechanical strengths of the spacers, it is proposed according to a further preferred configuration of the method according to the invention that reinforcements are embedded in the mold for the production of a spacer prior to the introduction of the expandable polystyrene.
To solve the initially mentioned objects, a device for producing a building component or shuttering body for the production of a wall structure including to oppositely located and substantially parallel, plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete, moreover, is essentially characterized by:
means for producing the spacers of polystyrene, in particular expandable polystyrene; and
means for producing the plate-shaped elements, comprising at least one mold for receiving the spacers and for introducing expandable polystyrene for forming the plate-shaped elements and connecting same with the spacers, or embedding the spacers in the plate-shaped elements, respectively.
It will thereby be feasible to do with a simple plant or device for treating or processing polystyrene, in particular expandable polystyrene, so as to enable the production of the building components or shuttering bodies according to the invention, in particular, in a cost-effective and reliable manner. As already pointed out above, a building component or shuttering body according to the invention can be substantially produced in a joint device, with the means for producing the spacers introducing polystyrene, in particular expandable polystyrene of an accordingly elevated density, into mold subregions provided for forming the spacers, wherein, after the production of the spacers, the plate-shaped elements are produced of expandable polystyrene and connected with the spacers, or the latter are embedded in the same.
As already indicated above, it may be provided according to a further preferred embodiment that separate means for producing the spacers are provided.
As already mentioned above, the present invention, moreover, relates to a wall structure comprised of a plurality of superimposed and/or adjacently arranged building components or shuttering bodies according to the invention or a preferred embodiment thereof.

SHORT DESCRIPTION OF THE DRAWINGS

In the following, the invention will be explained in more detail by way of exemplary embodiments schematically illustrated in the accompanying drawing. Therein:

FIG. 1 is a perspective view of a first embodiment of a spacer according to the invention, for a building component according to the invention;

FIG. 2 is a side view of the spacer according to FIG. 1;

FIG. 3 is a top view on a building component according to the invention, using a plurality of spacers according to the invention;

FIG. 4 is a perspective view of the building component according to FIG. 3;

FIG. 5 is a view of a modified embodiment of a spacer according to the invention, FIG. 5 a depicting a side view of the spacer in an illustration similar to that of FIG. 2 and FIG. 5 b depicting a section along line Vb-Vb of FIG. 5 a;

FIG. 6, in an illustration similar to that of FIG. 5, depicts another modified embodiment of a spacer according to the invention, FIG. 6 a again being a side view and FIG. 6 b a section along line VIb-VIb of FIG. 6 a;

FIGS. 7 and 8 depict views of further modified embodiments of spacers according to the invention for the production of building components or shuttering bodies according to the invention, again in side views similar to that of FIG. 2;

FIG. 9 is a schematic, partial top view on a modified embodiment of a building component according to the invention, using mutually crossing or intersecting spacers according to the invention;

FIG. 10, in an illustration similar to that of FIG. 9, is a top view on a modified embodiment of a building component according to the invention, using spacers extending obliquely or inclinedly relative to one another and arranged in the manner of a framework construction;

FIG. 11 is a schematic flow chart of a method according to the invention for producing a building component or shuttering body according to the invention; and

FIG. 12, on an enlarged scale, schematically illustrates the reception or embedment of an end region of a spacer according to the invention in a plate-shaped element for the production of a building component according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In FIGS. 1 and 2, a spacer or connection element is generally denoted by 1, wherein a plurality of such connection elements 1, as illustrated in FIG. 3, are used for the production of a building component or shuttering body 2, as will be discussed in more detail below.
The spacer represented in FIGS. 1 and 2 is comprised of a central, planar element or region 3 adjoined by end regions 4, which, in the embodiment illustrated, form a double-T-shape or I-shape together with the central, planar region 3.
In addition, reinforcing elements 5 are indicated in the region of the T-shaped end regions 4, said reinforcing elements providing an enhanced anchorage effect, in particular, if the spacers 1 are embedded in plate-shaped elements 6 and 7 of the building component 2.
Moreover, depressions or recesses 8 are indicated in edge regions of the central region 3 to subsequently receive, for instance, additional armoring or reinforcing rods, as will be discussed below.
From FIG. 3, it is apparent that a plurality of spacers 1 are embedded or received in the substantially parallelly arranged plate-shaped elements 6 and 7, wherein both the plate-shaped elements 6 and 7 and the spacers are made of polystyrene and, in particular, expandable polystyrene.
In order to take up the forces acting on the spacers 1 during the subsequent filling of the building component or shuttering body 2 with a settable mass, e.g. concrete, it is provided that the spacers or connection elements 1 are made of a polystyrene having a higher density than that of the plate-shaped elements 6 and 7. In doing so, a range of 50 to 250 g/l and, in particular, about 70 to 100 g/l, may be chosen for the density of the spacers 1, while polystyrene having a density of below 50 g/l and, for instance, about 20 to 30 g/l is used to obtain the usually desired insulation properties by the plate-shaped elements 6 and 7 designed as a lost shuttering.
From the illustrations according to FIGS. 3 and 4, of the building component or shuttering body 2, it is, moreover, apparent that the plate-shaped elements 6 and 7, on their upper and lower sides, are designed to include profiles formed by elevations or projections 9 and depressions 10, which cooperate with respectively corresponding profiles of building components 2 arranged beside, above or below the same, in order to provide a wall structure having an appropriate height extension by the stacking of such building components 2 one above the other.
FIG. 4, moreover, indicates the arrangement of an additional armoring or reinforcement rod 11. According to demands, several reinforcing rods may, of course, be arranged in the respective depressions or recesses 8 of the individual spacers or connection elements 1. Furthermore, when arranging building components 2 one above the other, additional reinforcing elements may also be incorporated in the vertical direction, which, if required, may be connected with the reinforcing elements arranged, for instance, in the horizontal direction in a manner similar to the reinforcing rod 11.
From the enlarged illustration according to FIG. 12, it is apparent that the T-shaped end region 4 of a just partially illustrated spacer 1 is accordingly embedded in the plate-shaped element 6 or 7, respectively, wherein, considering the fact that polystyrene, in particular expandable polystyrene, is used both for the spacer 1 and for the plate-shaped elements 6 and 7, a direct connection or weld or fusion is effected between the T-shaped end region 4 and the surrounding region of the material of the plate-shaped elements 6 and 7. Because of the connection provided by using the same material both for the spacer 1 and for the plate-shaped elements 6 and 7, forces occurring during the filling procedure and/or setting process will, thus, be introduced into the plate-shaped elements 6 and 7 over an enlarged partial area, as is indicated by the lines of force 12, so that no damage in the region of the reception of the, in particular, T-shaped end regions 4 in regard to tearing-out from the plate-shaped element 6 or 7 need be feared.
FIG. 5 depicts a modified embodiment of a spacer 13, wherein it is to be seen that the planar, central region adjacent the, in particular, T-shaped end regions again denoted by 4, is subdivided into two subregions 14 and 15 which are mutually offset in a central portion 16. The offset arrangement of the subregions 14 and 15 ensures that no linear passage through the spacer 13 is enabled such that an accordingly good resistance, in particular, against piercing of the spacer 13 or shooting through the same will be safeguarded.
Also in the embodiment illustrated in FIG. 5, additional reinforcements 5 are again indicated in the region of the T-shaped end pieces 4. Breakthroughs or recesses 8 are again provided for accommodating reinforcements.
In the modified embodiment represented in FIG. 6, it is apparent for a spacer 17 that the central, planar region is comprised of three relatively offset subregions 18, 19 and 20 so as to again prevent a linear passage through the spacer 17.
In FIGS. 7 and 8, further modified embodiments of spacers 21 and 22 are illustrated, for which it is apparent that by the arrangement of at least one breakthrough or recess 23 or 24 and 24′, respectively, it will each be ensured that a substantially linear passage through the spacer or connection element 21, 22 will again be impossible.
In the embodiment illustrated in FIG. 7, substantially circular breakthroughs 23 are arranged in a relatively offset manner, while in the embodiment according to FIG. 8, recesses or depressions 24 and 24′ mutually crossing in the central region are each provided substantially over one half of the thickness of the spacer 22.
In addition to providing the possibility of preventing linear passage, the breakthroughs or recesses 23 and 24, 24′, respectively, in the embodiments according to FIGS. 7 and 8, moreover, ensure that adjacent subregions or chambers between individual spacers 21 and 22 will be connected when being filled with the settable mass, by the settable mass entering the breakthroughs 23 and 24, so as to provide a mechanical connection between neighboring subregions separated from each other by the spacers 21 and 22.
Furthermore, the fire protection properties of the embodiments depicted in FIGS. 5 to 8 will be enhanced, since an immediate burning-through through curved or buckled or offset configurations is impossible, wherein an immediate breaking-through of a spacer 21 or 22 will likewise be avoided by the arrangement of breakthroughs 23 and 24, 24′, respectively.
In FIGS. 9 and 10, further modified embodiments of spacer arrangements between plate-shaped elements again denoted by 6 and 7, of a building component 2 are indicated. In the embodiment according to FIG. 9, mutually crossing or inter-secting spacers 25 are indicated, while in the embodiment according to FIG. 10, spacers 26 which are arranged obliquely or inclinedly relative to the substantially parallel elements 6 and 7 are shown. These spacers 25 and 26 are again embedded in the plate-shaped elements 6 and 7 via substantially T-shaped end regions 4, further forming being, for instance, realized in a manner similar that of the spacers illustrated in the preceding embodiments.
In order to achieve optionally increased strength characteristics, it may, moreover, be provided that reinforcement elements comprised, for instance, of fiber reinforcements or sieve-like reinforcing elements are embedded in the spacers 1, 13, 17, 21, 22, 25 and 26 by being respectively incorporated in the spacers 1, 13, 17, 21, 22, 25 and 26 at the production of these spacers, during the foaming procedure of the expandable polystyrene of elevated density.
In particular, when providing reinforcements, which may, for instance, be made of synthetic material or metal, spacers 1, 13, 17, 21, 22, 25 and 26 having accordingly reduced cross sections or reduced thicknesses will do yet while maintaining the required and, in particular, mechanical properties. For the central, planar region, thicknesses of about 5 to 20 mm and, in particular, 10 to 15 mm, will, for instance, do at accordingly elevated densities of the polystyrene, in particular expandable polystyrene, used for the production of the spacers 1, 13, 17, 21, 22, 25 and 26.
FIG. 11 schematically depicts a process diagram for the production of a building component or shuttering body 2, wherein, in a first step S1, the production of a spacer 1, 13, 17, 21, 22, 25 and 26 is effected, to which end polystyrene, in particular expandable polystyrene of an accordingly elevated density, is introduced into a mold.
After the production of the spacers 1, 13, 17, 21, 22, 25 and 26 in step S1 in a separate device, these spacers are placed in a mold for the production of the building component or shuttering body 2 in a step S2, after which, in a further step S3, the plate-shaped elements 6 and 7 are likewise formed by introducing expandable polystyrene into a mold corresponding with the plate-shaped elements 6 and 7. Due to the accordingly elevated temperatures occurring during the foaming procedure, a connection between the material of the plate-shaped elements 6 and 7 as well as the spacers likewise produced of expandable polystyrene of elevated density is immediately realized in the form of welding or fusing together as explained in detail with reference to FIG. 12.
Bearing in mind the method steps represented in the process diagram according to FIG. 11, a building component or shuttering body 2 can, thus, be produced using an accordingly simple device, wherein a separate device or, in general, means for producing the spacers 1, 13, 17, 21, 22, and 26 is provided according to step S1.
Moreover, means or device for producing the building component 2 by arranging the spacers in a suitable mold and subsequently foaming the plate-shaped elements 6 and 7 for connection with the end regions 4 of the spacers 1, 13, 17, 21, 22, 25 and 26 is provided according to steps S2 and S3. In this respect, the automatic transfer into the mold, of the spacers 1, 13, 17, 21, 22, 25 and 26 produced in the device according to step S1 may, for instance, be provided to perform steps S2 and S3.
Instead of the process diagram represented in FIG. 11, in which the spacers 1, 13, 17, 21, 22, 25 and 26 are produced in a separate device in step S1, a joint mold may be provided for the production of both the spacers 1, 13, 17, 21, 22, 25 and 26 and the plate-shaped elements 6 and 7, wherein polystyrene, in particular expandable polystyrene of an accordingly elevated density, is introduced into, and treated and processed in, the subregions of the mold, in which the spacers 1, 13, 17, 21, 22, 25 and 26 are to be produced subsequently, whereupon, in consecutive step S3, the plate-shaped elements 6 and 7 are formed by introducing expandable polystyrene of an accordingly lower density into the mold in correspondence with the plate-shaped elements 6 and 7, while effecting a connection with the spacers 1, 13, 17, 21, 22, 25 and 26, or embedment of the latter in the plate-shaped elements 6 and 7.
When providing such a joint mold for the production of both the spacers 1, 13, 17, 21, 22, 25 and 26 and the plate-shaped elements 6 and 7, the additional method step S2 of transporting or transferring the spacers 1, 13, 17, 21, 22, and 26 produced in a separate device in step S1 can be obviated. When using such a method and such a device, respectively, it must, however, be made sure that the starting materials, in particular expandable polystyrenes of different densities, will be available for the production of the spacers 1, 13, 17, 21, 22, 25 and 26 as well as the plate-shaped elements 6 and 7 in consecutive steps and different mold subregions.
Instead of the recesses 8 illustrated in the Figures, an accordingly modified number and/or form or shape may be provided for the recesses or depressions 8 to accommodate, for instance, armoring rods or reinforcing elements.
In addition to the circular or elliptical or rounded-off recesses or breakthroughs 23 and 24, 24′ shown in FIGS. 7 and 8, recesses or breakthroughs having accordingly modified, e.g. rectangular, square, etc., cross sections may be provided.
In addition to avoiding a substantial linear passage through a spacer by providing breakthroughs or recesses 23 and 24, 24′, such breakthroughs or recesses will also ensure an accordingly large saving of material for the formation of the spacers 21 and 22.
By forming both the spacers 1, 13, 17, 21, 22, 25 and 26 and the plate-shaped elements 6 and 7 each of polystyrene, in particular expandable polystyrene, an optionally required disposal of such building components or shuttering bodies 2, or wastes thereof, will also be facilitated in that no separation into individual elements or components is required, as has been the case with known embodiments.
It is, moreover, feasible to use a simple and cost-effective mode of realizing the processing of expandable polystyrene for the production of the spacers 1, 13, 17, 21, 22, 25 and 26, in particular, as opposed to known injection molding techniques.
Furthermore, the end regions 4, instead of comprising the T-shapes illustrated, may have modified shapes, whereby reliable embedding in the plate-shaped elements 6 and 7, respectively, will, in particular, be feasible by providing an appropriate thickness or dimension of the end region 4 relative to the central element or region 3 as is, in particular, illustrated in FIG. 12.

Claims

1. A spacer or connection element for a building component or shuttering body for the production of a wall structure including two oppositely located and substantially parallel, plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete, wherein the spacer is made of polystyrene, in particular expandable polystyrene, of elevated density.

2. A spacer according to claim 1, wherein the density of the expandable polystyrene of the spacer is selected to range between 50 and 250 g/l and, in particular, from about 70 to 100 g/l.

3. A spacer according to claim 1, wherein the spacer is comprised of a planar element designed with an increased thickness in its end regions relative to the region located therebetween, said end regions being receivable in the plate-shaped elements of the building component.

4. A spacer according to claim 3, wherein the spacer, in a cross section, is substantially double-T-shaped with the T-like ends being receivable in the plate-shaped elements.

5. A spacer according to claim 3, wherein the spacer is designed to comprise reinforcements in its end regions, between the planar region and the end regions.

6. A spacer according to claim 1, wherein the spacer is reinforced by reinforcing elements.

7. A spacer according to claim 6, wherein the reinforcing elements are comprised of loose, optionally hydrophilized, fibers embedded in the spacer.

8. A spacer according to claim 6, wherein the reinforcements are comprised of sieve-like or grid-like or net-shaped reinforcements or rods, which are embedded in the spacer.

9. A spacer according to claim 6, wherein the reinforcements are made of metallic or synthetic material.

10. A spacer according to claim 1, wherein the spacer is designed to include at least one recess, depression or breakthrough extending substantially normally to its direction of extension.

11. A spacer according to claim 10, wherein the spacer, in its planar, central region, is formed with at least one breakthrough to prevent the spacer from being penetrated by a linear element in its planar region.

12. A spacer according to claim 1, wherein the spacer is curved or cranked, or formed with relatively offset subregions, particularly in its central region.

13. A spacer according to claim 1, wherein the spacer has a thickness of less than 25 mm and, in particular, about 5 to 20 mm and, most preferred, 10 to 15 mm.

14. A building component or shuttering body for the production of a wall structure including two oppositely arranged and substantially parallel plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete, wherein it comprises at least two spacers according to claim 1 and the plate-shaped elements are made of polystyrene, in particular expandable polystyrene.

15. A building component according to claim 14, wherein the spacers are formed of an expandable polystyrene having an elevated density relative to the material of the plate-shaped elements.

16. A building component according to claim 14, wherein the density of the expandable polystyrene for the plate-shaped elements is selected to range between 10 and 50 g/l and, in particular, from about 20 to 30 g/l.

17. A building component according to claim 14, wherein the plate-shaped elements, on their upper and lower boundary edges, are at least partially provided with profiles cooperating with complementary profiles of a further building component arranged thereabove or therebelow.

18. A building component according to claim 17, wherein the profiles are comprised of substantially regularly arranged projections and depressions.

19. A building component according to claim 14, wherein the plate-shaped elements have different thicknesses.

20. A method for producing a building component or shuttering body for the production of a wall structure including two oppositely arranged and substantially parallel plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is filled with an, in particular, settable mass, e.g. concrete, characterized by the steps of:

producing spacers of polystyrene, in particular expandable polystyrene; and

forming the plate-shaped elements of polystyrene, in particular expandable polystyrene, in a mold, wherein the spacers are connected with, or embedded in, the plate-shaped elements in their end regions.

21. A method according to claim 20, wherein the spacers of expandable polystyrene are produced in separate molds.

22. A method according to claim 20, wherein the spacers are placed in a mold as a function of the plate-shaped elements.

23. A method according to claim 20, wherein reinforcements are embedded in the mold for the production of a spacer prior to the introduction of the expandable polystyrene.

24. A device for producing a building component or shuttering body for the production of a wall structure including to oppositely located and substantially parallel, plate-shaped elements connected by at least two spacers, wherein the free space between the plate-shaped elements is fillable with an, in particular, settable mass, e.g. concrete, characterized by:

means for producing the spacers of polystyrene, in particular expandable polystyrene; and

means for producing the plate-shaped elements, comprising at least one mold for receiving and producing the spacers and for introducing expandable polystyrene for forming the plate-shaped elements and connecting same with the spacers, or embedding the spacers in the plate-shaped elements, respectively.

25. A wall structure comprised of a plurality of super-imposed and/or adjacently arranged building components or shuttering bodies according to claim 14.