WO1990011419A1

WO1990011419A1 - Building element for walls, and structure obtained therefrom

Info

Publication number: WO1990011419A1
Application number: PCT/IT1990/000032
Authority: WO
Inventors: Romeo Mariani
Original assignee: Romeo Mariani
Priority date: 1989-03-24
Filing date: 1990-03-22
Publication date: 1990-10-04
Also published as: AU5338090A; EP0465505A1

Abstract

The cavities (2a, 24) of a building element are filled with a mix (4) of heat-insulating and sound-deadening materials, preferably consisting of pumice and/or volcanic lapilli, in granular and/or powdery form. In a variation, the building element is just made up of said mix, and featured by a slab profile. The improved building element, obtained in this way, shows optimal features as far as sound-proofing, heat insulation, and heat resistance are concerned; there are no contraindications on its use, since it is made up of totally inert materials.

Description

"BUILDING ELEMENT FOR WALLS, AND STRUCTURE OBTAINED THEREFROM"

TECHNICAL FIELD

This invention is conceived in the framework of heat insulation, i.e. the technique adopted to reduce heat exchange with the external environment through outer and/or inner walls (partitions, floors, etc.) of a building.

Such a technique consists in coating walls with insulating materials, or in adopting equivalent building devices.

BACKGROUND ART

Known techniques are adopted to reduce heat exchange with the external environment, through outer and/or inner walls (partitions, floors, etc.) of a building. Such techniques usually consist in coating walls with insulating materials, or in adopting equivalent building devices.

For instance, walls may be insulated by means of slabs or panels of insulating material; the insulating effect of such arrangement may be improved by the presence of air spaces, nearly stagnant, suitably made among the layers, or even by a radiant shield made up of a thin sheet of specular aluminium (thickness between 0.1 and 0.05 nuns) or of another reflecting metal fitted on the front surface of the panel on the outer side.

The construction of walls with hollow bricks, which may be associated with the above-mentioned slabs and/or panels, is common, for such bricks show a low thermal conductivity coefficient together with a sufficient strength and fire resistance even at high temperatures. A technique is also known, which provides for the realization, inside the walls (usually the vertical ones), of an interspace which is filled with inert materials, or with synthetic materials (e.g. polystyrene), or with expanded clay.

For insulating the upper floor of buildings towards the outside, use is often made of materials consisting of synthetic resins (in granular form), or of expanded clay, or of refractory inert materials applied on the upper face of the floor.

In the field of prefabrication,load-bearing floor panels are used, made of a vibrated concrete mix which may be lightened with polystyrene foam or polyurethane foam.

Other building elements are also known, in some cases having such a size allowing them to be classified as panels, made up of two coaxial jackets, one inside the other, mutually connected by transversal baffles; the whole body made up of said jackets and baffles is made either by baking clayey mixes, or, preferably, by means of concrete bound with cement. In that case, the heat exchange between the vertical faces of the building element, of the above type, is limited by stagnant air inside the cavities defined by said jackets; other technical arrangements are known, which provide for filling these cavities with granules of synthetic resin, e.g. polystyrene foam.

In conclusion, heat insulation is aimed at reducing heat transmission as much as possible, through the walls of a building, by conduction, convection and radiation, i.e. limiting the so-called coefficient of apparent heat conduction.

The known arrangements described above turn out to be quite complex, not always reliable both concerning heat resistance and their duration (specially in the case of the use of materials based on synthetic resins); finally, they result to have remarkable costs mainly due to their realization and laying.

DISCLOSURE OF THE INVENTION

A main object of this invention is to present an improved building element, shaped in such a way as to effectively reduce heat exchange among its faces, so to be heat-resistant and finally to be sound-deadening.

Another main object of this invention is to present an improved building element, which, besides complying with the above requirements, is only a little more expensive and heavier than the corresponding element available on the market.

A further main object of this invention is to present the building element, which does not involve complications and/or constructing arrangements to make partitions, floors, walls and the like, for the construction of a building structure.

Yet another object of this invention is to present the new building element which does not show any contraindication about its use. The above objects are achieved, according to the invention, through an improved building element for making partitions, floors, walls and the like, made in a first embodiment, which features cavities communicating with the outside.

The cavities are filled with a mix made up of heat- insulating and sound-deadening materials, in granular and/or powdery form, and of at least one binder suited to bind these materials among themselves, as well as to make the same mix to adhere to the surfaces defining the cavities.

Preferably, said materials are made up of pumice or volcanic lapilli, or of pumice and volcanic lapilli mixed together in whatever relative percentage of weight or volume.

In a second embodiment of the invention, the building element is made up of a mix of heat-insulating and sound- deadening materials, in granular and/or powdery form, showing a slab shape.

Furthermore this element can bear a metal reinforcement buried in it.

The building element, provided by the second form of realization, shows, as to heat exchange among its faces, an apparent heat conduction coefficient lower than that achievable by the techniques and/or arrangements of heat insulation mentioned above.

The element obtained by the second form of realization is heat-resistant as well (in fact it is made of refractory materials) , and its sound-deadening properties are suited to make its use profitable as far as the limitation of unpleasant effects of noise pollution is concerned. The structure obtained by the claimed building element, presents a mechanical strength equal to the requirements of the regulations in force concerning building structures and therefor remains unchanged with the passing of time.

BRIEF DESCRIPTION OF DRAWINGS

The features of the invention are pointed out below, with particular reference to the drawings attached herewith, where:

- fig.l shows, schematically and as an example, the phase of filling the cavities of hollow tiles with a mix composed of heat-insulating and sound-deadening materials, and at least one binder;

- fig.2 shows, schematically and partially, according to a perspective view, a partition and a floor built by means of the tile being the subject of this invention;

- fig.3 and 4 show, in a perspective view, the tile presented according to respective and different cross sections;

- fig. 5a, 6a, 7a, show, according to front views, as many building elements being the subject of this invention, while figures no. 5b,6b,7b, show, in perspective view, parts of walls respectively built with the elements shown by fig. 5a,6a,7a.

- fig. 8, 9, 10, 11 show, in a perspective view, as many types of the element in question, in a second embodiment;

- fig. 12, 13 show, in perspective view and as an example, the realization of panellings, made by means of the element shown in fig. 8, 9, 10, and 11, for insulating an outer wall and a floor respectively.

- fig. 14 shows a perspective view of a part of a partition made by means of the element provided by the second embodiment;

- fig. 15 shows, in a perspective view, according to a cross section and a top view, a further variation of said second form of realization;

- fig. 16, 17 and 18 respectively show, in perspective view, according to a cross section and a top view, a further variation of said second form of realization.

MODES FOR CARRYING OUT THE INVENTION

With reference to fig. 1, no. 1 indicates tiles, particularly hollow tiles, characterized by cavities or holes 2 usually passing through.

It is known that tiles are building materials obtained by baking pieces made of clayey mixes, which, besides their properties concerning mechanical strength, also show interesting properties as far as heat insulation and sound-deadening are concerned.

No. 3 generically indicates known means, for instance, including a hopper 3a, suitable for filling the cavities 2 with a mix 4 made up of heat-insulating and sound-deadening materials, and of at least one binder, suited to bind said materials among themselves, as well as to make the same mix to adhere permanently to the surfaces 2a defining said cavities.

Said materials are preferably made up of pumice, in granular and/or powdery form, or of volcanic lapilli, in granular and/or powdery form, or of pumice and lapilli together in the above-mentioned forms. It is known that pumice is an acidic effusive rock, white, composed of glass and rare single crystals. It is originated from lava very rich of gases which, when cooling off, are released from rocks with the consequent formation of a great number of small hollow spaces which are often exceeding the glass itself in volume, making the material porous and light (it has a specific weight of about 0.69 g/cu.cm.).

It is a very good heat insulator and sound deadener, furthermore it is refractory.

To obtain pumice in granular and/or powdery form, it is sufficient to submit pumice to grinding, as it is available in the natural state.

Pumice, in granular and/or powdery form, is mixed with a suitable binder, preferably, for instance, a liquid mix based on gypsum, lime, refractory cement, etc. As already mentioned above, the mix of pumice and binder is introduced into the cavities 2 of tiles 1: see fig. 1; still in this latter figure, no. 14 generically indicates known levelling means suited to remove the mix coming out of the outer ends of the cavities. As an example, in fig. 1 the tiles are placed on a conveyor belt 5 and properly separated by spacers 6.

The activation of the binder, after a prefixed time, makes it possible to bind the granules and/or powders of pumice, as well as to make the mix so obtained to adhere permanently to the surfaces 2a defining the cavities 2.

In fig. 1, tiles with four holes are shown; it is understood that what has been said above is also true for any kind of hollow tile, e.g. tiles la with six holes (fig.2), tiles lb with two holes (fig. 3), tiles lc known as hollow flat tiles or hollow clay blocks (fig.2), or whichever type of hollow tile, for instance the so-called lug bricks Id (fig.4). As already mentioned above, instead of granular and/or powdery pumice, volcanic lapilli may be profitably used, which, as it is known, are basically fragments of vitreous and rocky volcanic materials which may occur, in nature, also in the form of a single crystal having a size between 2 and 30 mms.

It is also provided for the realization of improved tiles in which said heat-insulating and sound-deadening materials are consisting of pumice and volcanic lapilli in any mutual percentage of weight or volume.

Figures no. 5a, 6a, 7a are showing further building elements, made up of two jackets 20, 21, respectively first and second, with the second one inner and coaxial, as to the first one, mutually connected by cross baffles 23.

The complex composed of the jackets 20, 21 and the baffles 23 is a whole body and may be made either by baking clayey mixes, or by concrete bound with cement.

The above-mentioned elements are featured by cavities 24 which are filled, in the same manner as described above, with a mix of materials preferably consisting of pumice and/or volcanic lapilli, in granular and/or powdery form, and of at least a binding agent, suited to bind said materials among themselves as well as to make the same mix to adhere permanently to the surfaces 24a defining said cavities 24.

The elements 5a, 6a, 7a are different only in the profile of horizontal walls 20a of the outer jacket 20.

The improved elements, obtained as said above, are mutually assembled to build walls or partitions indicated, in figures no. 5b, 6b, 7b, by the reference number 30. The shape of the building elements shown in the drawings attached herewith, both concerning the cross section and dimensions (length, width, and height) is to be considered as an example and not a limitation. In fig. 8 and 9, no. 101 and .102 indicate two elements, made by the second embodiment suggested, showing a rectangular section, both horizontally and crosswise.

Said elements 101 and 102 are consisting of said mix of heat-insulating and sound-deadening materials, in granular and/or powdery form, preferably pumice and/or volcanic lapilli.

Said mix may also be composed of pumice and volcanic lapilli mixed together in any mutual percentage of weight or volume.

The elements 101 and 102 are different just in their thickness (the element indicated by 102 is thicker) and in that the element 101 shows one of its greater faces, indicated by 101a, without any unevenness or roughness, i.e. smooth, as the experts of the field mean by "smooth", while the element 102 shows both greater surfaces 102a, 102b, smooth.

The element 101 is particularly suitable for construction of panellings 103 (fig. 12) to insulate associated adjacent walls 104, minding that the surface 101a of the element 101 should be oriented towards the inside of the room 105; thus the inner surface of the panelling 103, being smooth, does not require any further finishing, i.e. it is finished. Results being equal, (particularly as to heat transmission and sound deadening) the thickness of the panelling 103 is remarkably smaller than the thickness of the insulating walls obtained so far by known techniques.

The element 102 is particularly suitable for the construction of partitions 106 (fig. 14); in this way, both surfaces 106a, 106b of every partition result to be smooth.

In fig. 10, 16, 17, 18, by no. 107 and 117 two further variations of the element in question are indicated. In particular, the element 107 (fig. 10) is defined by a lateral portion 108 and by an upper portion 109 disposed side by side lengthwise as well as joggled in steps lenghtwise and vertically.

Said portions are so designed to be fixed in joints to the corresponding portions of adjacent elements shown, as an example, in the panelling 110 in fig. 13 which results to be laid on a floor 111 in order to insulate the latter.

In fig. 16, 17, 18, the element 117 basically forms a pair of lateral portions 118 and an upper portion 119 disposed side by side lengthwise; the lateral portions

118 are disposed symmetrically to the sides of the upper portion 119.

The lateral 118 and upper 119 portions have a similar rectangular section, on a longitudinal plane.

The lateral portions 118 are joggled in steps as to the upper portion 119 lengthwise and vertically.

More in detail, the upper portion 119 forms an upper projection 119a over the plane defined by the upper surfaces of the lateral portions 118, with a truncated- cone cross section, and a front projection 119b, external as to the plane defined by the front surfaces of the lateral portions 118, with a truncated-cone cross section.

The lateral portions 118 form, at the bottom, a hollow 118a, with truncated-cone cross section, corresponding to the upper projection.119a but having a section suited to receive the latter easily, and, at the back, a further hollow 118b, with truncated-cone horizontal section, corresponding to the front projection 119b, but having a section suited to receive the latter.

The hollows 118a, 118b of the element 117 are suited to receive in a free joint respectively the projections 119a, 119b of the vertically and laterally adjacent elements,so to compose walls or partitions by interposing a suitable binder between the surfaces which result to be opposite after said fixing.

The clearance between every hollow and the related projection is allowed to make adjustments, when building a wall or a partition, vertically and crosswise. Also in this case, as the element 117, the greater surfaces are smooth, so that when a wall or a partition are built, no further finishing is required.

In order to increase the mechanical strength of the element being the subject of this invention, at least a metal reinforcement 112 is provided, (see fig.11),buried in the same element, which may be projecting at one of its heads.

With the element 113 so obtained, (see fig. 11 again), it is possible to build partitions, walls, and the like, showing a mechanical strength at least equal to the requirements of the regulations in force concerning building structures. - 12 -

In fig. 15, prefabricated elements 114 are shown, still made of a mix of heat-insulating and sound- deadening materials, preferably reinforced, having the same height as that between the floors 115, between which the same elements are fitted.

One, or more, of said elements is provided with an opening 116 which is fitted with a suitable frame, not shown.

The shape of the building elements shown in figures 8 to 18, both concerning cross section and dimensions (length, width, height) is to be considered as an example and not a limitation.

INDUSTRIAL APPLICABILITY

As a matter of fact, the featuring point of this invention, with reference to the first form of realization suggested, is the realization of improved building elements obtained from building elements already available on the market of the type provided with cavities which are filled with the above-described mix.

The improved building element, obtained as described above, shows, as far as heat exchange between its faces is concerned, an apparent heat conduction coefficient lower than that achievable through the techniques and/or arrangements of heat insulation mentioned above.

Furthermore, the same building element is heat- resistant (in fact it is made of refractory materials) and shows such sound-deadening properties which make its use profitable in the framework of the limitation of unpleasant effects of noise pollution. According to further variations of the two forms of realization of the building element presented, instead of pumice and/or volcanic lapilli, it is also possible to use granules of expanded clay, or granules of synthetic resin, or granules and/or .powders of heat- insulating and sound-deadening materials.

It is also possible to profitably use vermiculite, in granular and/or powdery form, which, as it is known, is a particular sort of chlorite which exfoliates, by calcination, so providing a soft, refractory, insulating and sound-deadening aggregate.

In these latter variations, it is possible to use synthetic binders instead of those mentioned above.

There are no contraindications about the use of the element, being the subject of this invention, since pumice and/or volcanic lapilli are totally inert.

In conclusion, the heat exchange among inner rooms I, delimited for instance by partitions 7 and floors 8, and/or walls 30, made by the use of the improved building element being the subject of this invention, and the outside E, is remarkably lower than that obtained so far by the known arrangements.

It is to be pointed out that the sound-proofing of such inner rooms, still as to the outside, turns out to be more than acceptable, at the optimal limit if compared with the sound-deadening levels of conventional techniques.

The optimal heat resistance of said partitions, floors and walls, is a consequence of the optimal heat resistance of the improved building element used to build the same partitions, floors and walls.

The characteristic points of the building element presented, which are also found in partitions, floors, walls and the like, built with said elements, and in the structure obtained by the latter, remain unchanged with the passing of time. Pumice and volcanic lapilli are available, in nature, at extremely interesting costs, which, together with the easy realization of the improved element presented (consisting either of a common tile, or of an element of the type shown in figures no. 5a, 6a and 7a, whose cavities are filled with the mix described above) makes it possible to achieve the same building element at comparable, if not lower, costs as to the known techniques of heat insulation.

The floors, partitions,walls, etc. obtained by the element in question, show a weight per unit of surface which does not involve an overload on the load-bearing elements 10 of the building structure made by the use of such elements.

The outer scored surfaces of the tile and the outer surfaces of the jackets 20 (fig. 5a, 6a, 7a) do not result to be altered and/or modified in any way as to the original element; thus, it is not necessary to resort to constructing arrangements when building partitions, floors, walls and the like.

SUBSTITUTESHEET

Claims

1) Improved building element for construction of partitions, floors, walls and the like, and structure obtained by such element, the latter being of the type provided with cavities (2,24), communicating with the outside, characterized in that said cavities (2,24), are filled with a mix (4) made up of heat-insulating and sound-deadening materials, in granular and/or powdery form, and of at least a binder suited to bind said materials among themselves as well as to fix the same mix permanently to the surfaces (2a,24a) defining said cavities (2,24).

2) Building element for construction of walls, partitions, floors, panellings and the like, and structure obtained by said element, characterized in that it is made up of a mix of heat-insulating and sound-deadening materials, in granular and/or powdery form, showing a slab profile.

3) Building element for construction of walls, partitions, floors, panellings and the like, and structure obtained by said element, characterized in that it is made up of a mix of heat-insulating and sound-deadening materials, in granular and/or powdery form, in which a metal reinforcement is buried, with said mix showing a slab profile.

4) Element as in claim 1, characterized in that said heat-insulating and sound-deadening materials are consisting of pumice.

SUBSTITUTESHEET 5) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of volcanic lapilli.

6) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of pumice and volcanic lapilli.

7) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of vermiculite.

8) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of pumice and/or volcanic lapilli and/or vermiculite.

9) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of expanded clay.

10) Element as in claims 1, 2 or 3, characterized in that said heat-insulating and sound-deadening materials are consisting of synthetic resins.

11) Element as in claims 1, 2 or 3, characterized in that said binder is consiting of gypsum.

12) Element as in claims 1, 2 or 3, characterized in that said binder is consisting of lime.

13) Element as in claim 1, characterized in that said binder is consisting of refractory cement.

14) Element as in claim 1, characterized in that said binder is consisting of a synthetic binder.

15) Element as in claims 3 or 4, characterized in that said slab profile forms at least a lateral portion and an upper portion, disposed side by side lengthwise as well as joggled in steps lengthwise and vertically, with said portions suited to be fixed by joints to the corresponding portions of adjacent elements.

16) Element as in claim 15, characterized in that it includes a pair of lateral portions disposed symmetrically to the sides of said upper portion.

17) Element as in claim 16, characterized in that said upper portion forms an upper projection over the plane defined by the upper surfaces of the lateral portions, and a front projection, external as to the plane defined by the surfaces of the lateral portions, and with said lateral portions forming a hollow at the bottom, corresponding to the upper projection, and a further hollow at the back, corresponding to said front projection, and a further hollow at the back, corresponding to said front projection, said hollows being suited to receive, in a free joint, the projections of the vertically and laterally adjacent elements respectively, for building a wall or a partition, by interposing binders.

18) Element as in claim 17, characterized in that said upper and lateral projections respectively show a truncated-cone cross section and a truncated-cone horizontal section, with said lower and back hollows respectively showing truncated-cone cross and horizontal sections.

19) Element as in claims 3 or 4, characterized in that said slab profile forms rectangular sections, both horizontally and crosswise.

20) Element as in claim 19, characterized in that said slab profile is provided with openings and/or recesses.

21) Element as in any of the claims from 15 to 20, characterized in that at least one of the greater surfaces of the same element result to be smooth.

22) Element as in claim 3, characterized in that said reinforcement is projecting from at least one head of the same element.

SUBSTITUTESHEET