WO2001083905A1

WO2001083905A1 - Building block and method for producing the same

Info

Publication number: WO2001083905A1
Application number: PCT/EP2001/003135
Authority: WO
Inventors: Holger GÖDEKE; Achim Wichtler; Norbert König
Original assignee: Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Priority date: 2000-04-28
Filing date: 2001-03-19
Publication date: 2001-11-08
Also published as: US20030150185A1; EP1278924A1; DE10020956A1; DE10020956B4

Abstract

The invention relates to a wall block and to a method for producing the same. The inventive wall block has a lower mass than conventional wall blocks as well as excellent insulating properties. Said wall block consists of a lightweight material selected from the following: expanded glass, pearlite, expanded clay or mixtures thereof. Said lightweight material is obtained by liquid phase sintering or fusing pre-expanded expanded glass granulate, expanded clay granulate, pearlite or mixtures thereof and forms an aerated structure which serves as an insulating core. Said insulating core is at least partially surrounded by a shell body consisting of a conventional wall block material. The inventive wall block is produced by filling a corresponding shell body with the lightweight material and heating the pre-expanded lightweight material, which has a residual expanding agent content of at least 0.1 mass % and is used in the form of a granulate, to above the softening temperature of the granulate. An additional volume expansion takes place and the surfaces of the granulate are fused.

Description

Brick and process for its manufacture

The invention relates to a brick and method for its production, such bricks, like conventional bricks, can also be used in the construction of single and multi-family houses and in drywall construction, and can have excellent insulating properties.

Masonry or bricks have proven themselves technically and economically in the construction sector, as brick masonry, brick ceiling bricks or hollow brick bodies for a relatively long time. Over the years, these components used have been continuously improved to meet the increasing demands of the market. These improvements related in particular to the insulation properties and essentially to the thermal insulation. The developments led to porous lightweight bricks with filigree perforation patterns, which are limited, however, particularly for reasons of strength. Minimum bulk densities and web thicknesses must be observed in order to guarantee sufficient strength and safety during transport and processing, and to prevent undesired destruction from occurring before processing and sufficient structural properties can still be achieved.

Are such filigree stones with low used thick, this also adversely affects sound insulation and longitudinal sound insulation.

Lightweight concrete blocks or aerated concrete also have limits, since the desired thermal insulation properties and the required strengths are contradictory to each other and consequently the corresponding advantages and disadvantages must be weighed against each other and lead to a corresponding compromise.

From the point of view of thermal and acoustic insulation, a greater wall or wall thickness could theoretically be selected, but this leads to loss of area in any case.

To fulfill the required thermal insulation, it is common to use external organic or inorganic thermal insulation composite systems on such brick walls or ceilings, which, however, in turn lead to an increase in thickness and to an increased expenditure of time and money. Such two-shell wall structures, which are formed from a base layer with glued and / or mechanically fastened insulation layer with additional external plaster, can be used without problems in the renovation of old buildings, in which the disadvantages mentioned can be accepted, ■ for the new building which does not have to be taken into account with regard to old buildings, this is again only a disadvantageous compromise.

Attempts have also been made to produce expanded clay or pumice hollow blocks in which there is integrated insulation without any additional increase in thickness. For such integrated insulation ω ω M IV) P- P-

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pulls on the respective end face areas, that is to say arranged above and below in the interior of the formwork body, can be fixed.

In the second alternative, a mixture consisting of 60 to 95% by mass of a lightweight aggregate, selected from expanded glass, perlite and expanded clay and optionally also mixtures thereof, mixed with 40 to 5% by mass of a soda water glass can be poured into a formwork body or a mold and then, when heated with the formation of soda-lime glass by liquid phase sintering, the light aggregate particles are connected in a network-like manner and the insulation core can be formed in this way. If the insulating core is produced in a mold, it can, as already described above, be pressed and held in the formwork core, which is open at least on the upper end face, after demolding.

Before heating, the mixture can optionally be dried at temperatures in the range from 50 to 95 ° C. The sintering then takes place in the temperature range between 550 ° C. and 1000 ° C., this taking place in a period between 0.1 to 5, preferably in the range between 0.1 to 0.5, hours.

For the rest, a corresponding process for the production of molded articles from light materials is described in detail in DE 197 12 835 AI, and full use should be made of the corresponding disclosure content.

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The granules thus prepared are placed in a mold consisting of at least two parts or in a formwork body made of a material normally used for bricks or bricks and then heated in the form or the formwork body. The heating takes place in a temperature range in which the respective granules soften, that is to say the corresponding softening temperature is reached and maintained. As a result of the heating, a further volume expansion of the starting granulate occurs and the granulate surfaces sinter together, so that the finished insulation core is available after removal from the mold or is formed inside the formwork core.

Since the pre-expanded starting granulate continues to experience an increase in volume as a result of the heating, it is expedient to fill out the mold or the formwork with the starting granulate only with a volume fraction of at least 80% and at most 95%, preferably with at least 85% by volume. As a result, a closed-pore structure which completely fills the preferably at least two-part shape or the formwork body can be obtained during heating and the desired properties can be achieved.

After the mold or the formwork body has been filled, taking care to ensure that the contents of the formwork core or mold are filled evenly, the pre-expanded starting granulate, which has at least 80% of the final volume, preferably at least 85% of the final volume, is in the form or the scarf body warmed and expanded further.

It is advantageous to heat in two stages to carry out, with heating in the two stages with different heating rates. However, the heating rate should be constant in both stages. This ensures uniform heating over the entire volume and an even structure. Thus, in a first heating stage a higher heating rate, for example 5 K / min, and in the second heating stage with a lower heating rate, for example 2 K / min. The heating in the ER most level should be up ^'to temperatures of 650 ° C and in the second stage up to about 750 ° C when pre-expanded foam glass has been used as a raw granulate.

After the required softening temperature for the granules has been reached, the corresponding temperature is maintained for a certain period of time, approximately 30 minutes, so that the granule surface sinters together safely.

Following the heating, slow cooling should take place before the molded body is removed from the mold or with the insulating core formed in the formwork body, in order to avoid internal stresses in the finished insulating core as far as possible. ^'' The required cooling time down to ambient temperature can be up to 10 h. The starting granulate used should be used in a grain size range from 1 to 8 mm, preferably from 2 to 4 mm, a uniform grain size in the narrow tolerance range possibly requiring shorter heating and holding times and ensuring a uniform structure.

The amount of blowing agent required in the manufacture of such an insulation core should be in the range between ω ω tv> DO μ- P> cn o cπ o cπ o cπ

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For example, the formwork body can be provided with an appropriate inner coating before filling or pressing in a prefabricated insulation core or the insulation core can be coated on the outside with a suitable material, for example corrugated cardboard can be used, which can also be used as packaging.

In addition, the number of cavities or hollow chambers, even with a relatively low thermal conductivity, is considerably smaller than is the case with conventional masonry bricks. This means that the thermal resistance can be increased by approx. 30% in comparison to conventional porous ^' lightweight brick bricks, which, if the thermal insulation values to be achieved in the future increase according to the low-energy house standard, will result in no further increase in wall thickness and consequently no reduction in the usable room area leads .

With the bricks according to the invention, one can

3 relatively small stone bulk density <600 kg / m the required stone strength class for one and two-family houses can be easily met.

Regardless of the starting materials used, this heat treatment not only achieves a bond between the light aggregate particles or the granulate, but also connects the insulation core to the formwork body with the formation of a glass melt.

As also already indicated, there are several alternatives for how a brick according to the invention can be produced. For example, the Formwork bodies (made of clay, for example) are filled with preheated granulate (blown glass granulate) during the cooling process, with the waste heat from the firing process being used for preheating. After filling, the mixture is then heated again to the softening temperature of the granules or the temperature required for the liquid phase sintering.

A filling funnel made of austenitic steel with sufficient heat resistance can be used for filling.

In particular, the expandable glass granules that can be used have good flow behavior, so that the formwork bodies can be filled in a very short time of a few seconds. However, the softening temperature of the granules should not be exceeded during filling.

Conveniently, the heating takes place in a rapid fire furnace, e.g. a roller oven, with a filling device in the cooling area, in which several brick formwork bodies can be thermally treated next to each other standing vertically on kiln boards.

For smaller brick factories that have discontinuous ovens, such as alternately operated bogie hearth furnaces, the brick formwork should be automatically removed from the bogie wagon after the brick firing and fed to a separate filling station. After filling the formwork with the light aggregate or granulate, the formwork can be placed on a firing surface. which is automatically placed on a bogie and the filled bogie is fed to the final heating phase (tempering).

The invention will be described in more detail below with the aid of examples.

Show:

Figure 1 shows an example of a scarf body of a brick according to the invention;

Figure 2 shows another example of a brick according to the invention, consisting of the formwork body and insulating core with formed hollow chambers and reinforcement channel;

3 shows a brick according to the invention consisting of two parts, as a so-called moving brick in two achievable sizes for length compensation;

Figure 4 shows another example of a brick according to the invention;

Figure 5 shows an example of a brick according to the invention, with a tongue and groove connection and

Figure 6 shows a structure of several bricks according to Figure 5.

The insulation cores 2 can, as described in DE 197 12 835 AI, be produced in a separate form or in the formwork 1 for a brick according to the invention. For this, the already mentioned Lightweight aggregates are coated with the sintering aid and either added to the formwork body 1 or this mass is brought into the desired shape by an appropriately suitable shaping process (for example axial pressing, extruding, casting) and then dried. This green body can be subjected to a subsequent thermal treatment, in which liquid phase sintering takes place, as a result of which the light aggregate particles are selectively connected to one another. Occurs during sintering _. an ion exchange between the liquid phase and the particles, which leads to a substance-specific bond, so that a correspondingly porous structure of low bulk density and relatively increased strength is obtained.

If the insulation core 2 is made from pre-expanded granules without the addition of a binding agent or sintering aid, either a form that is as divisible as possible or the formwork body 1 is filled with the corresponding pre-expanded granules. The filling takes place in a loose fill, whereby the filling height is as uniform as possible, e.g. by shaking, should be observed.

During the temperature treatment of this loose fill, a new volume expansion (expansion process) occurs and the starting material foams again, so that the bulk density is further reduced. The starting granulate has about 85% of the pore volume of the finished insulation core 2. Similar to EPS production, starting from a porous pre-product in granular form, there is again an increase in volume of approx. 15% during shaping. Specifically, a brick according to the invention, as also shown in the figures, can be produced in a preferred form in such a way that a formwork body 1 made of fired clay is filled with expanded glass granulate, which is available under the trade name "Liaver". The expanded glass granulate has a bulk

3 density of 220 kg / m and is used with a grain size between 2 and 4 mm. The expanded glass granulate used has an increased residual sheet content, which should be at least 0.1% by mass.

The loose bed in the shuttering core 1 is leveled out by shaking.

A brick blank prepared in this way can then be heated in a discontinuous chamber furnace or in a discontinuously operated push-through furnace with a heating rate of 5 K / min to 650 ° C and subsequently with a heating rate of 2 K / min to about 750 ° C, the softening temperature of the granules are kept at this temperature over a period of approx. 30 min, the surfaces of the granules melting or sintering and the starting material being additionally inflated, so that a further increase in volume compared to the loose bed can be achieved, and this correspondingly in the interior of the formwork body 1 trained insulation core 2 completely fills the inner volume of the scarf body 1.

After the heating and holding phase, cooling takes place within the furnace chamber over a period of approx. 10 h.

If necessary, the bricks can then be ground flat fenced, palletized and ready for dispatch, whereby the upper and lower end face of the bricks can also be processed in the form of a tongue and groove connection.

The bricks thus obtained have the properties listed in Table 1.

1 shows a formwork body 1 without an insulation core 2. The scarf body 1 can, for example, be extruded from clay in the form shown and cut to the appropriate format, the cutting width here specifying the height of a corresponding brick.

The scarf body 1 can be made of clay and then, as already described, fired in an oven. After the firing, the starting material for the insulation core 2 can be filled and the corresponding subsequent thermal treatment can be carried out.

In the example shown in FIG. 1, a plurality of webs 3 have been formed on the inner wall of the formwork body 1, these here running parallel to the direction of extrusion and, in addition to increasing the strength of the formwork body 1, also a secure fixation for the person to be trained or to be accommodated Insulation core 2 can represent.

However, the webs 3 can also be arranged in an inclined shape, or can be provided with contours, which can be groove-shaped incisions or wave forms in order to further improve the hold of the insulation core 2. The shawl body 1 shown here can not only be open on its upper end face, as shown, but also the lower end face can be open, wherein the filling of the shawl body 1 can then take place in a mounted position on a base plate on which the filled one Scarf body 1 can then be thermally treated in an oven.

In addition, diametrically opposed semicircular recesses 4 are shown, wherein shapes other than the semicircular shape can also be used.

These recesses 4 can be the starting point for a reinforcement channel 10, such as was formed in the example shown in FIG. 2. Such reinforcement channels 10 can then be used to guide reinforcement elements, which extend over a plurality of bricks arranged next to one another, and to increase the support from a large number of such bricks.

In addition, hollow chambers 8 are shown in this example, which, in addition to reducing the mass and improving thermal insulation, can also be used for anchoring reinforcement elements.

Both the reinforcement channels 10 and the hollow chambers 8 can be formed using appropriately shaped cores, for example made of a metal with a higher melting temperature than the insulating core material during the heat treatment. In this case, such cores can be formed on a shape that can be placed on the upper end faces of the scarf body 1. CJ ω PO N) μ * P> cπ o Cπ o cπ o Cπ

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^' By the method according to the invention, the hollow chambers can be arranged in a defined position without any problems, so that an alignment of the hollow chambers with respect to hollow chambers in masonry stones which are arranged above and below form continuous cavities guided inside the wall, through which vertically aligned cavities are also formed Reinforcement elements or installations (building services) can be performed.

The reinforcement elements can be coupled to the stone composite using a filling mortar and thus largely protected against corrosion.

Since the reinforcement elements at least completely from

Insulation core material are enclosed, thermal bridges can be avoided.

Table 1 property profile

* 14mm interior plaster, 20mm insulation plaster, 300mm brick, mortar with LM 21

Claims

claims

1. Brick, in which a lightweight building material, which is selected from expanded glass, perlite, expanded clay or mixtures thereof, which forms a pore structure as an insulating core (2) from a formwork core by liquid phase sintering or sintering of pre-expanded expanded glass granulate, expanded clay granulate, perlite or mixtures thereof (1) is made of a conventional brick material, at least partially enclosed.

2nd Brick according to claim 1, d a d u r c h g e k e n n z e i c h n e t that the formwork body (1) is formed from fired clay, clay and clay mass as well as wood concrete, lightweight concrete from expanded clay, pumice or similar light aggregates.

3. brick according to ^' claim 1 or 2, characterized in that the scarf body (1) is partially or completely open on at least its upper end face.

4. Brick according to one of claims 1 to 3, characterized in that webs (3) and / or grooves are formed on the inner wall of the Schalkδrpers (1).

5. Brick according to one of claims 1 to 4, characterized in that on the upper and / or lower end faces of the formwork body (1) recesses (4) are formed for carrying out reinforcement elements.

6. Brick according to one of claims 1 to 5, characterized in that the formwork body (l ¹ , 1 ^,! ) Is formed in two parts with a plurality of longitudinal webs (5) aligned parallel to one another, with each pair being adjacent between these longitudinal webs (5) , alternating air or an insulation core (2) are present and a part of the scarf body (1 ") can be inserted into the second part of the scarf body (1 ^{, τ} ) by appropriate meandering arrangement of the insulation cores (2).

7. brick according to one of claims 1 to 6, characterized in that in the insulation core (2) handle pockets (7), reinforcement channels (10) and / or hollow chambers (8) are formed.

8. Brick according to one of claims 1 to 7, characterized in that double webs (9) are formed on the formwork core (1).

9. brick according to one of claims 1 to 8, characterized in that the upper and lower end faces are formed as a tongue and groove connection (11, 12).

10. Brick according to one of claims -1 to 9, characterized in that there is an acoustic decoupling between the inner wall of the formwork core (1) and the insulation core (2).

11. Brick according to one of claims 1 to 10, characterized in that the insulating body (2)

3 has a bulk density <600 kg / m.

12. Brick according to one of claims 1 to 11, characterized in that the insulating body (2) is a closed-pore structure.

13. Brick according to one of claims 1 to 12, characterized in that light aggregate particles selected from expanded glass, perlite and expanded clay are network-connected with one another to form a soda-lime glass.

14. A method for producing a brick according to one of claims 1 to 13, characterized in that a formwork body (1) in its interior with thermally pre-expanded expanded glass, thermally pre-expanded perlite or thermally pre-expanded expanded clay, with a residual blowing agent content of at least 0.1 mass. %, filled as granules and then heating up to temperatures above the softening temperature of the granules, which leads to a further volume expansion and to the sintering of the granule surfaces.

15. A method for producing a brick according to one of claims 1 to 13, characterized in that thermally pre-expanded expanded glass, thermally pre-expanded pearl or thermally pre-expanded expanded clay with a residual blowing agent content of at least _. 0.1 mass% when granules are placed in a mold; subsequently heating up to temperatures above the softening temperature of the granules, which leads to a further volume expansion and to the sintering of the granule surfaces, and the molding obtained as Insulating body (2) is removed from the mold and pressed into a formwork body (1).

16. The method according to claim 14 or 15, so that the volume in the interior of the formwork body (1) or a mold before heating is filled with at least 80% and a maximum of 95% with the granules.

17. The method according to any one of claims 14 to 16, characterized in that a granulate with grain sizes in the range 0.25 to 8 mm is used.

18. The method according to any one of claims 14 to 17, characterized in that a residual blowing agent content in the range 0.1 to 1 mass% is maintained.

19. The method according to any one of claims 14 to 18, characterized in that a thermally pre-expanded expanded glass granulate obtained from recycled glass with the addition of an organic blowing aid is used.

20. The method according to claim 19, characterized in that sugar derivative is used as blowing agent.

21. The method according to claim 18 or 19, characterized in that the thermal pre-expansion is carried out so that the blowing agent portion results as the residual content of the blowing agent.

22. The method according to any one of claims 14 to 21, characterized in that using the heat from the firing process for the production of a shutter core (1), preheated granules are filled in the shutter core (1) and further heating until the softening temperature of the Granules and for fusing the granulate surfaces is carried out.

23. A method for producing a brick according to any one of claims 1 to 13, characterized in that a mixture consisting of 60 to 95% by mass of a lightweight aggregate selected from expanded glass, perlite and expanded clay with 40 to 5% by mass of one Sodium water glass filled into a formwork body (1) and when heated to form a soda lime glass by liquid phase sintering, the light aggregate particles are connected in a network-like manner and the insulation core (2) is formed in the formwork core (1).

24. A method for producing a brick according to any one of claims 1 to 13, characterized in that a mixture consisting of 60 to 95% by mass of a lightweight aggregate selected from expanded glass, perlite and expanded clay with 40 to 5% by mass of a sodium water - Glasses placed in a mold, in a heat treatment with the formation of soda-lime glass by liquid phase sintering, the light aggregate particles are connected in a network-like manner and the molded body thus obtained after demolding in a formwork shell (1), as an insulation core (2) is pressed.

25. The method according to claim 23 or 24, characterized in that the heat treatments at temperatures between 550 and 1000 ° C - carried out over a period of 1 h to 5 h and the molded body or insulating core (2) is sintered.