WO2001040593A1

WO2001040593A1 - Wall element and method for making such a wall element

Info

Publication number: WO2001040593A1
Application number: PCT/BE1999/000154
Authority: WO
Inventors: Marc Schildermans
Original assignee: Gojo, Naamloze Vennootschap
Priority date: 1999-11-30
Filing date: 1999-11-30
Publication date: 2001-06-07
Also published as: AU1539800A

Abstract

Wall element, characterised in that it mainly consists of a basic body (3) made of a hardened substance, whereby this basic body (3) is provided with at least one cover layer (4) which is at least composed of granulated particles (5) and a quantity of plastic (6) which functions at least as a binding agent.

Description

Wall element and method for making such a wall element

> The present invention concerns a wall element, as well as a method for making such a wall element.

The invention m the first place concerns concrete prefab elements, but m a more general way it also concerns otnei 10 types of building components for walls

The invention aims a new type of wall element which offers several advantages compared to the conventional concrete wall elements known until now i

To this aim, the invention concerns a wall element characterised m that it consists of a basic body made of a hardened substance, whereby this basic body s provided with at least one cover layer which is at least composed of

20 granulated particles and a quantity of plastic which functions at least as a binding agent.

The basic body preferably consists of concrete, and, m a preferred embodiment, of cellular concrete or a similar

")C porous substance

Preferably, the granulated particles together with the plastic so to say form a single mass which extends m layers over the surface of the basic body when cured, 30 whereby the granulated particles are fixed to the basic body by means of the above-mentioned plastic.

Thanks to the above-described design, the wall element according to the invention offers several advantages 5 compared to conventional wall elements, and m particular ? -

compared to conventional prefab wall elements made of cellular concrete.

A first advantage consists in that, thanks to the use of a cover layer with plastic, a surface is obtained which is easy to maintain as it can be washed, as opposed to conventional plates made of cellular concrete, whose surface is very porous and easily absorbs dirt which moreover is difficult to remove.

Another advantage of the invention consists m that the nature of the granulated particles can be selected as a function of the application. Thus, for example, by using a natural stone for the granulated particles, it is possible to create a surface which is particularly compression- resistant and impact-resistant, as opposed to the surface of cellular concrete, of which pieces are easily knocked- off .

Another advantage consists in that the mass of the granulated particles and plastic can be coloured as desired, so that it is possible to make wall elements having different colours. It is also possible to create different effects by using granules for the granulated particles which differ in colour, in size as well as in shape . ,

Another major advantage consists in that the cover layer offers a good protection against weather conditions, so that damp stains arising on the inside are entirely excluded.

According to the most preferred embodiment, there are free passages in the cover layer, such that the surface against which the coating is provided remains connected with the amb ent air. Preferably, the passages are hereby obtained as only a small quantity is used in relation to che quantity of granulated particles, such that there remains an open structure in between the granules . Such an open structure offers the advantage that the material of the basic body remains connected with the ambient air, so that possible moisture which has gathered m this basic material from the inside, caused by moisture on the inner side, can escape to the outside. It is clear that this advantage wil] be particularly useful when a basic body is used which is made of cellular concrete or such

Also, the known vapour pressure problems which arise in the conventional prefab elements made of cellular concrete which are painted on the outside and which are thus sealed practically air-tight, no longer occur m the above- mentioned embodiment of the present invention.

However, what precedes does not exclude that, according to a variant, the cover layer is made entirely tight, for example when the application of the wall elements allows for it .

Although the invention is particularly useful m applications whereby the cover layer is provided on the outside of a building or such, it is clear that such a wall element can also be used m other applications whereby the cover layer is directed to the inside.

The invention a.lso concerns a method for making such a wall element, which method will be further described in detail

In order to better explain the characteristics of the invention, the following preferred embodiments are described as an example only without being limitative in any way, with reference to the accompanying drawings, m which

figure 1 schematically represents a building with wall elements according to the invention; figure 2 represents a cross section of a wall element of the building m figure 1, in particular according to line II-II m figure 1, figure 3 shows a view according to arrow F3 n figure 2 , figure 4 represents the part which is indicated by F4 m figure 2 to a larger scale, figure 5 schematically represents how the wall element of figures 2 and 3 can be made; figure 6 represents a variant of the part which is represented m figure 4, but when the wall element is put flat, figure 7 represents a section according to line VII-

VII m figure 6 to a larger scale.

As represented in figure 1, the invention is meant m particular for self-supporting plate-shaped wall elements 1, with which prefab constructions, as the represented building 2, can be erected in a relatively short time.

As represented in figures 2 to 4 , the wall element 1 consists of a basic body 3 which is made of a nardened substance, preferably cellular concrete. According to the invention, this basic body 3 is provided with a cover layer 4 which, as can be seen in the detail of figure 4, is composed of granulated particles 5 which are fixed on the surface 7 concerned of the basic body 3 by means of plastic 6 The granulated particles 5 can hereby be of any nature whatsoever, both as far as the material of which they are made is concerned as well as the method according to which they are obtained. The basic material may for example consist of a natural stone, such as marble, roller gravel or blue stone, but it may just as well consist of another type of material, such as granulated plastic or glass, or also of a mixture of different materials. Further one can take a material which is granulated as such, or materials which are granulated so as to form the above-mentioned particles 5, for example by breaking them and/or bv grinding them.

The plastic 6 is preferably a plastic on the basis of polyurethane , epoxy or such, but other plastics are not: excluded of course, on condition that they guarantee a sufficient bond and if required also a sufficient sealing.

Preferably, the cover layer 4 is obtained from a mixture of the granulated particles 5 with the plastic 6. Thus is ensured that there is always a plastic film around the particles 5, so that these particles 5 as such practically cannot absorb any dirt . The colour or shade of the particles 5 is still visible through the transparent film however, at least when the plastic film is not coloured.

It is clear that, according to a variant, the cover layer 4 can be coloured with colorants, either by colouring the plastic 6, or by treating the granulated particles with a colorant, for example with pigment.

In the embodiment of figure 4, the cover layer 4 has free passages 8, such that the surface 7 remains connected with the ambient air, so that, as explained in the introduction, moisture can always escape to the outside through the cover layer 4.

As can be seen in figure 2, the wall elements 1 can be provided with tooth-shaped and groove-shaped coupling edges, 9 and 10 respectively, in a known manner.

Further, also fenders can be provided to the wall elements 1, for example in the shape of profiles 11, as is schematically represented in figure 4. These profiles 11 prevent that pieces of the cover layer 4 are knocked off and moreover provide for a nice, straight edge.

In the case where the wall elements 1 are made as prefab elements, they may have a length of a few metres, a thickness of for example 10 to 20 cm and a height of some ten centimetres .

According to figure 2, the cover layer 4 is only provided on one side, but according to a variant it may also be provided on several sides, for example on the inside and on the outside.

In order to obtain a good coverage by means of the cover layer 4, but nevertheless also provide for an embodiment which is economically advantageous, the cover layer 4 preferably has one or several of the following characteristics :

- the thickness of the cover layer 4 is at least twice the thickness of the average size of the granulated particles 5 ; the granulated particles 5 have an average size of 2 to 5 mm; - the cover layer 4 has a thickness of 2 to 10 mm. The above-mentioned wall elements 1 are preferably made by first forming the basic body 3 out of a hardening substance, such as concrete or such. This basic body 3 can be shaped m at mould or a vibrating mould, or it can be sawn out of a larger block of already hardened material. Subsequently, a mixture of a quantity of granulated particles with a quantity of non-cured plastic is made

Next, m order to form the cover layer 4, this mixture is provided on the basic body 3 m the shape of a flat layer This can be done in any way whatsoever. For practical reasons, the basic body 3 is hereby preferably put flat and the cover layer 4 is spread out or rolled out over it, for example as is schematically represented m figure 5. Subsequently, the cover layer 4 is made to cure, or at least the plastic 6, which has for a result that a cured, adhering layer remains on the surface 7.

The above-mentioned passages 8 can hereby be obtained by selecting the quantity of plastic 6 such during the formation of the above-mentioned mixture that the formed mass is not entirely filled with plastic, and the plastic 6 is only provided around the particles 5 as a film so to say. Naturally, the quantity of plastic 6 to be used hereby not only depends on the quantity of granulated material, but also on factors such as the grain size of the particles 5 and the liquidity of the plastic 6. It is clear that the right proportions between the amount of plastic 6 and the particles 5 can be experimentally determined.

According to a special aspect of the invention, special precautions are taken m order to prevent the plastic o from running out on the surface 7, while the cover layer 4 is being provided, such m order to prevent that the above- mentioned passages 8 are obstructed due to the running out of the plastic 6. According to the example represented _ n figures 6 and 7, this is realised by providing a relief to the surface 7 To this end, recesses, m this case m the shape of grooves 12, are formed m the surface 7, having a width B which is smaller than the size or diameter of most of the granulated particles 5.

Tnu_ is obtained, as represented in figure 7 that th-_ plastic film 6A provided around the particles 5 cannot make contact with tne surface 7 there where the grooves 12 are situated, and consequently cannot run out.

The grooves 12 also offer the advantage that the material of the basic body 3 can breath more easily, as they function so to say as aeration ducts, via which moisture can be lateral Ly discharged up to those places where there are passages 8.

The grooves 12 can be made during the formation of the basic body 3, or they are provided m this basic oody 3 after it has been formed, for example by means of sawmq, milling or grinding. The relief can also be obtained in another way than by means of grooves 12, for example by sandblasting the surface 7.

The present invention is by no means limited to the above- described embodiments represented m the accompanying drawings; on the contrary, such a wall element and th-i method for manufacturing it, can be made m all sorts of variants while still remaining within the scope of tne invention. Thus , for example, it is not excluded to make use of bricks or blocks for the basic body 3 instead of large panels; with these bricks can then be formed a wall by laying or gluing them.

Although the granulated particles 5 are preferably relatively small, it is not excluded either to make use of larger particles, such as small boulders or such.

In the case where the cover layer 4 may be entirely tight, this can be realised either by using such a large quantity of plastic 6 that the formation of any passages 8 is excluded, or by providing an extra layer of entirely sealing plastic under or above the above-mentioned cover layer 4.

According to an embodiment which is not represented, it is also possible to first provide a layer of plastic on the surface 7, after which the granulated particles 5 are scattered in the plastic which has not cured yet and are possibly pressed therein.

The above-mentioned passages 8 can possibly also be made by means of a specific manipulation after an entirely tight cover layer 4 has been provided on the surface 7. Thus, such passages 8 can for example be formed by drilling holes in the cover layer 4.

Claims

1. Wall element, characterised m that it mainly consists of a basic body (3) made of a hardened substance, whereby this basic body (3) is provided with at least one cover layer (4) which is at least composed of granulated particles (5) and a quantity of plastic (6) which functions at least as a binding agent.

2. Wall element according to claim 1, characterised m that the basic body (3) is made of concrete.

3. Wall element according to claim 1 or 2 , characterised in that the basic body (3) is made of cellular concrete or a similar porous substance.

4. Wall element according to any of the preceding claims, characterised m that the granulated particles (5) and the plastic (6) form a mixed, cured mass.

5. Wall element according to any of the preceding claims, characterised m that the granulated particles (5) are not only connected to one another, but are also attached to the basic body (3) by means of the above-mentioned plastic (6).

6. Wall element according to any of the preceding claims, characterised m that the plastic (6) consists of a synthetic material on the basis of polyurethane, epoxy or such.

7. Wall element according to any of the preceding claims, characterised m that there are free passages (8) through the cover layer (4), such that the surface (7) of the basic body (3) against which the cover layer (4) is provided is freely connected with the ambient air.

8. Wall element according to claim 7, characterised in that the above-mentioned plastic (6) mainly forms merely a film

(6A) around the granulated particles (5) and thus connects them mutually and fixes them on the surface (7) of the basic body (3) , whereby the quantity of plastic (6) is selected such that there remain passages (8) as mentioned above between the granulated particles (5) .

9. Wall element according to any of the preceding claims, characterised in that the surface (7) of the basic body (3) against which the cover layer (4) is provided has features which prevent the plastic (6) from running out on this surface (7) .

10. Wall element according to claim 9, characterised in that the above-mentioned features consist in that the above-mentioned surface (7) of the basic body (3) is made in relief, whereby recessed are formed in the above- mentioned surface (7) having a width or a diameter which is smaller than the diameter of most of the granulated particles (5) .

11. Wall element according to claim 10, characterised in that the above-mentioned relief is formed by providing grooves (12) in the above-mentioned surface (7) .

12. Wall element according to any of the preceding claims, characterised in that it is made in the shape of a self- supporting prefab wall plate.

13. Wall element according to any of the preceding claims, characterised in that the cover layer (4) is provided on only one side of the basic body (3) .

14. Wall element according to any of the preceding claims, characterised in that the cover layer (4) has one or several of the following characteristics:

the granulated particles (5) are made of a natural stone; the particles (5) and/or the plastic (6) are artificially coloured; the thickness of the cover layer (4) is at least twice the thickness of the average size of the granulated particles (5) ; the granulated particles (5) have an average size of 2 5 mm; the cover layer (4) has a thickness of 2 to 10 mm.

15. Method for making a wall element according to any of the preceding claims, characterised in that it comprises at least the following steps:

forming a basic body (3) out of a hardening substance; - making a mixture of a quantity of granulated particles

(5) with a quantity of non-cured plastic (6); providing the above-mentioned mixture on at least one side of the basic body (3) formed as mentioned above in the shape of a flat layer; - and letting this mixture cure on the basic body (3), such that a cover layer (4) is created which adheres to the surface (7) of the basic body (3) .

16. Method according to claim 15, characterised in that, while the above-mentioned mixture is formed, the quantity of plastic (6) is selected such that, after the cover layer (4) has been provided and has been made to cure, there remain air passages (8) in the cover layer (4) .

17. Method according to claim 16, characterised in that features are found on the surface (7) of the basic body (3) which restrict the running out of the plastic (6) over said surface (7), which features consist in that a relief is provided in the surface (7) .

18. Method according to claim 17, characterised in that the above-mentioned surface (7) is provided with grooves (12) which are formed in the surface (7) concerned after the basic body (3) has been manufactured.