WO2010109270A1

WO2010109270A1 - Proceeding for manufacturing an insulating building product for buildings and building product thereby obtained

Info

Publication number: WO2010109270A1
Application number: PCT/IB2009/051248
Authority: WO
Inventors: Marco Tarello
Original assignee: Marco Tarello
Priority date: 2009-03-25
Filing date: 2009-03-25
Publication date: 2010-09-30

Abstract

An insulating building product for buildings and a proceeding for manufacturing the same, in which at least one insulating element (4) is interposed between a first block (2) and a second block (11); the blocks and the insulating element are linked to each other through suitable engagement means (5) consisting of an expansion insert (6), extruded and injected in a semifluid form into a respective cavity (7) formed in the blocks (2, 11) and in the insulating element (4), and subsequently hardened.

Description

PROCEEDING FOR MANUFACTURING AN INSULATING BUILDING PRODUCT FOR BUILDINGS AND BUILDING PRODUCT THEREBY OBTAINED

5 The present invention relates to a proceeding for manufacturing an insulating building product for buildings and to an insulating building product obtainable with said proceeding.

10 In particular, the present invention is suitable for use in the building field and more specifically for houses, buildings and similar constructions requiring an appropriate thermal and/or acoustic insulation from the surrounding environment.

15

Generally, manufacture of the outside main walls of said buildings takes place through formation of a first wall designed to constituite the inner face of the wall, made up of bricks vertically piled up according

20 to horizontal courses. A series of insulating panels is subsequently applied onto the external side of the first wall, by suitable fastening means, so as to define a substantially continuous insulating layer. Then a second wall of bricks is erected which is

25 designed to constitute the outer face of the wall. The second wall of bricks can be either directly manufactured against the insulating panels thus forming a single body, or manufactured to a predetermined distance from the insulating panels so as to define an

30 air space for aeration and/or arrangement of electric elements or other elements.

Another ^' known and widespread technique for manufacturing insulating walls contemplates formation

35 of an inner brick-made wall and, subsequently, of an outer brick-made wall spaced apart from the first one, so as to define an air space therebetween. Finally, an expandable insulating material is poured into the air space, which material solidifies thereby defining an insulating layer.

In order to obtain better insulation and simplify the building operations, a type of insulating building product for buildings has been put on the market which substantially comprises two blocks usually made of a brick material such as mixed clay for example, between which a body of insulating material consisting of foamed polystyrene is interposed.

For instance, in Patent EP 1085137 it is disclosed a building product provided with suitable mechanical constraint members, adapted to steadily keep the blocks in engagement with the respective insulating material.

In particular, this solution involves a series of small metal springs associable on the opposite sides of a respective insulating layer and each of which has respective elastically deformable projecting tongues. The tongues of each spring are bent inside surface cavities formed in the blocks and urged to get hooked on respective undercuts defined at the cavities themselves. In this manner a steady mechanical constraint is defined between said springs previously fastened to the insulating material and the brick-made blocks.

While this solution is able to form the insulating building product in a simple manner and quickly, it however has serious drawbacks, mainly connected with the presence of the small metal springs. In fact, an important increase in the production costs results from the fact that high amounts of springs are required to be produced and stored in order to meet the requirements of a large-scale production, also taking into account the fact that different springs for different types of products may be necessary. Also to be added to the above costs are those for machinery and all working operations needed in order to obtain automated engagement of the small springs to the insulating panels and hooking of same to the brick-made blocks. It is also to be considered in this regard that the springs as well as the operations for fastening the same to the insulating panels must be carried out with great accuracy in order to ensure correct execution of hooking during the step of assembling them to the brick-made blocks.

The technical task of the present invention is to conceive an insulating building product for buildings and a proceeding for manufacturing this insulating building product that are capable of obviating the mentioned drawbacks.

Within the scope of this technical task, it is an important aim of the invention to conceive an insulating building product for buildings having optimal thermal-insulation and soundproofing features, which at the same time is structurally simple and can be obtained at reduced costs.

In particular, the present invention aims at manufacturing an insulating building product that is free from mechanical hooking members that must be stored and subsequently coupled to the insulating material during manufacture of the building product.

Another important aim of the invention is to conceive a proceeding for manufacturing an insulating building product which is quick, simple and of reduced production costs.

The technical task mentioned and the aims specified are substantially achieved by a proceeding for manufacturing an insulating building product for buildings, comprising the features set out in claim 1 and/or in one or more of claims 2 to 11.

The technical task mentioned and the aims specified are in addition achieved by an insulating building product for buildings comprising the features set out in claim 12 and/or in one or more of claims 13 to 22.

Description of some preferred but not exclusive embodiments of an insulating building product for buildings in accordance with the present invention is now given hereinafter by way of non-limiting example and illustrated in the accompanying drawings, in which:

- Fig. 1 is an elevation front view partly in section of an insulating building product for buildings according to a first embodiment;

- Fig. 2 is an elevation front view partly in section of an insulating building product for buildings according to a second embodiment; - Fig. 3 is a diagrammatic top plan view of an industrial plant in which a preferential proceeding for manufacturing a building product in accordance with the present invention is carried out.

With reference to the drawings, an insulating building product for buildings in accordance with the present invention has been generally identified with 1.

Referring particularly to the first embodiment shown in Fig. 1, the insulating building product 1 comprises a first block 2 preferably consisting of a clay brick. It would be recognised that block 2 can be made of any other building material suitable for performing its load-bearing and insulating function, such as stone, ceramic, terra cotta, concrete, etc.

Shown in Fig. 1 is a first block 2 consisting of a partially hollow body 3, of the type commonly referred to as "hollow brick" and having a plurality of inner through openings 3a usually oriented in a vertical direction on installation.

The product 1 further comprises at least one insulating element 4 associated with the first block 2 and made of foamed polyester, for example. In this case too it is to be pointed out that the insulating element 4 can be made of any material suitable for performing its thermal and/ acoustic-insulation function.

Preferably, the insulating element 4 is a plate-shaped element having a respective flat inner surface 4a coupled to an inner surface 2a of the first block 2 and a flat outer surface 4b opposite to the inner surface 2a.

The first block and the insulating element 4 are steadily linked to each other through suitable engagement means 5.

The engagement means 5 comprises at least one expansion insert β extending in a cavity 7 formed in the first block 2 and in the insulating element 4.

Advantageously, as shown in the drawings, the engagement means 5 comprises one or more, and preferably at least two, expansion inserts 6 extending in respective cavities 7.

In more detail, each cavity 7 is defined by a first hole 7a which is preferably a through hole, formed in the first block 2 and by a second through hole 7b formed in the insulating element 4. The first hole 7a extends over the whole width of the first block 2, passing through all openings 3a present along the path of the hole itself. The second hole 7b extends in alignment with, and in the continuation of the first hole so as to define a straight cavity 7 therewith. Alternatively, holes 7a, 7b can be obliquely oriented through the first block 2 and the insulating element 4.

The expansion insert 6 has at least one first anchoring portion 8 located at the first hole 7a and a second anchoring portion 9 located at the second hole 7b.

In more detail, in the example in Fig. 1, a plurality of anchoring portions 8 is provided, each of them being disposed in a respective inner opening 3a, while the second anchoring portion 9 is disposed at an end of the expansion insert 6 and extends at least partly on said outer surface 4b of the insulating element 4.

In a possible alternative embodiment not shown, the first block 2 is made of a solid brick, in which case the first and second anchoring portions 8, 9 are disposed in respective opposite end portions of the expansion insert 6, the first anchoring portion 8 acting against a corresponding outer surface 2b of the first block.

Shown in Fig. 2 is a second preferred embodiment of the insulating building product 1.

In this embodiment the insulating element 4 is interposed between the first block 2 and a second block 11 preferably consisting of a hollow brick too, provided with respective through openings 3a. However use of solid bricks is also possible in this case too.

Cavity 7 is defined by the first hole 7a formed in the first block 2, the second hole 7b formed in the insulating element 4 and a third hole 7c formed in the second block 11, in alignment with, and in the continuation of the first and second holes 7a, 7b. In this case too, holes 7a, 7b and 7c are mutually in register in axial-extension relationship, so as to form a straight cavity 7, and the building product 1 is preferably provided with two or more cavities 7 parallel to each other or oriented in an oblique direction.

Extending within each cavity 7 is said expansion insert 6, provided with at least one respective first anchoring portion 8 disposed in the first hole 7a and at least one second anchoring portion 9 disposed in the third hole 7c.

The expansion insert 6 can be provided with a series of first and second anchoring portions 8, 9, each of which is housed in one of the inner openings 3a of the respective first or second block 2, 11. Referring particularly to Fig. 2 by way of example, the expansion insert 6 has a plurality of first anchoring portions 8 disposed one after the other, each in a respective opening 3a of the first block 2 and a pair of second anchoring portions 9, each housed in one of the openings 3a of the second block 11, close to the insulating element 4.

The expansion insert 6 consists of an elongated body having a plurality of bulges 6a defining said anchoring portions 8, 9. These bulges βa seen in cross-section advantageously have a greater size than the width of the respective first, second and/or third holes 7a, 7b, 7c.

In other words, bulges 6a housed in the inner openings 3a or out of cavities 7 constitute an enlargement of the section of element 6 to prevent mutual sliding between insert 6 and cavity 7. In this way, the anchoring portions 8, 9 ensure a steady engagement of blocks 2, 11 and of the insulating element 4.

The expansion insert 6 is preferably made of plastic material, based for example on polypropylene, silicone, chemical glue, chemical cement, or other suitable materials that, when inserted into cavity 7 are in a pasty or semifluid state, to be then submitted to an expansion and hardening process.

Referring particularly to Fig. 3, there is shown an industrial plant 12 for putting into practice a proceeding for manufacturing the above described building product 1, according to the embodiment seen in Fig. 2. First of all, at least one first block 2 which has been previously formed is provided on a conveyor belt 13.

In the example in Fig. 3, simultaneously with the step of providing the first block 2, also the second block 11 is prearranged on the conveyor belt 13.

Subsequently, the insulating element 4 is directly provided on belt 13 and brought into contact with the first and second blocks 2, 11 at the respective inner surfaces 2a, 4a, 11a. This step is carried out at an assembling station 13a where respective clamps diagrammatically identified with 14 keep the first block 2 and the insulating element 4 steadily in engagement with each other.

Then belt 13 moves blocks 2, 11 and the insulating element 4 to an engagement station 13b where said components are steadily engaged with each other. This step is carried out through creation of a pair of through cavities 7 by means of a- drilling operation preferably made by one or more drills or other suitable drilling device 15 that by a single operation forms the first, second and/or third holes 7a, 7b, 7c of each cavity 7.

Alternatively, the first and third holes 7a, 7c can be formed during the step of making blocks 2, 11 before the step of baking them. The second hole 7b too can be obtained in the insulating element during manufacture of same.

It should be noted that at least in the embodiment in

Fig. 2 cavity 7 is not necessarily a through cavity, because the third hole 7c of the second block 11 can extend until about half way of the second block 11.

At this point, an expansion insert 6 is inserted into each cavity 7 to anchor the blocks and the insulating element 4 together through formation of said anchoring portions 8, 9 in the first and second blocks 2, 11.

In more detail, the anchoring portions 8, 9 are made through permanent set of the expansion insert 6 that, as above said, in this step is in a semifluid or pasty state.

In fact, insertion of the expansion insert 6 takes place by distributing a plastic material in a semifluid or pasty form at the inside of cavity 7. Subsequently, the plastic material is expanded inside cavity 7 and gradually hardened so as to form an elongated stiff body.

Distribution of the plastic material can be carried out through injection of same by means of a nozzle 16 connected to an extrusion apparatus for example, not shown as known by itself. Nozzle 16 is axially insertable into cavity 7 to gradually deliver the plastic material in said cavity 7, which material is preferably heated so that it reaches the semifluid state adapted to enable easy extrusion of same from the nozzle, while keeping a sufficient consistency in order to avoid undesirable percolations that would impair the structural integrity of the insert being made.

As clearly shown in Fig. 4, during distribution, nozzle

16 can be gradually pulled out of cavity 7, preferably at a speed Vl lower than the delivery speed V2 of the plastic material from the nozzle itself. Thus, as soon as the material so injected into cavity 7 adheres against one of the inner walls of the first block 2, of the insulating element 4 and/or of the second block 3, it is submitted to an expansion and swelling effect at the inside of openings 3a and/or against the outer surfaces 2b, 4b, so as to increase its cross section thus giving rise to formation of the anchoring portions 8, 9 having a greater size than that of cavity 7.

By cooling of the material laid down in cavity 7, solidification of the expansion insert 6 is caused, as well as definitive anchoring of the insulating element 4 to blocks 2, 3.

Alternatively, distribution of the plastic material can be carried out by mixing at least two components close to nozzle 16 or immediately upstream of said nozzle, which components, once in contact with each other, initiate a chemical cross-linking reaction giving rise to hardening. In addition or alternatively, the plastic material being distributed may comprise at least two components that, mixed with each other close to nozzle 16 and/or in cavity 7, can react generating gases that expand in the material thus causing a volume increase and forming the anchoring portions 8, 9.

Said components, such as epoxy resins with the respective catalysts for example, are not described in detail as they are available on the market in different forms and types.

Subsequently, the building product 1 thus formed is picked up from the conveyor belt 13 by means of a mechanical handling device 17, to be transferred to a subsequent station for packaging of the finished product .

For manufacture of the building product 1 according to the preferred embodiment shown in Fig. 1, unlike that which has been previously said, the step of inserting element 6 is carried out by making the first anchoring portion 8 in one of the inner openings 3a of the first block 2, and making the second anchoring portion 9 on the outer surface 4b of the insulating element 4, in the absence of the second block 3. To this aim, a counter-mould can be moved close to the outer surface 4b of the insulating element, to facilitate moulding of the second anchoring portion.

The present invention achieves important advantages.

In particular, it will be recognised that blocks 2, 11 are engaged with the insulating element 4 without additional elements, made and stored at a time preceding their use. ϊn fact, the expansion insert 6 delivered in a pasty form into cavity 7, enables a very steady engagement to be ensured between the components, thus eliminating use of additional mechanical hooking members. As a result, the building product 1 is simpler from a structural point of view and can be manufactured at lower costs.

In addition, the proceeding for manufacturing the building product 1 appears to be very simple and quick because particular care and accuracy is not required during the assembly. In fact, formation of the hole and delivery of the deformable insert 6 take place while blocks 2, 11 are maintained coupled to the insulating element 4, without any possibility of misalignment between the blocks themselves.

Claims

C L A I M S

1. A proceeding for manufacturing an insulating building product for buildings, comprising the steps of:

- providing at least one first block (2);

- providing at least one insulating element (4);

- moving the first block (2) and the insulating element (4) close to each other; and - steadily engaging the first block (2) with the insulating element (4); characterised in that said step of steadily engaging the first block (29 with the insulating element (4) comprises the steps of: - forming at least one cavity (7) in the first block

(2) and in the insulating element (4);

- distributing a plastic material in a semifluid form at the inside of the cavity (7);

- expanding said plastic material at the inside of the cavity (7); and

- hardening the plastic material so as to form an expansion insert (6).

2. A proceeding as claimed in the preceding claim, wherein the step of distributing the plastic material is carried out through injection of the plastic material by means of a nozzle (16) inserted into said cavity (7) .

3. A proceeding as claimed in one or more of the preceding claims, wherein said nozzle is gradually pulled out of the cavity during injection of the plastic material to a lower speed than the delivery speed of the plastic material from the nozzle to cause expansion of the injected plastic material.

4. A proceeding as claimed in one or more of the preceding claims, wherein during the distributing step the plastic material is heated to be brought to the semifluid state; said expanding and hardening steps taking place during cooling of the plastic material distributed in the cavity (7).

5. A proceeding as claimed in one or more of the preceding claims, wherein the step of distributing the plastic material is carried out through mixing of at least two components in said cavity (7); said hardening step taking place following a cross-linking reaction initiated by mixing of the two components.

6. A proceeding as claimed in one or more of the preceding claims, wherein the step of distributing the plastic material is carried out through mixing of at least two components in said cavity (7); said expanding step being carried out by gases generated following a reaction initiated by mixing of the two components.

7. A proceeding as claimed in one or more of the preceding claims, wherein said step of forming at least one cavity (7) is carried out by drilling the first block (2) and the insulating element (4) previously moved close to each other, to form respective through holes (7a, 7b) disposed consecutively in alignment.

8. A proceeding as claimed in one or more of the preceding claims, wherein following the expanding step, there is formed at least one first anchoring portion (8) of the expansion insert (6) in at least one inner opening (3a) exhibited by said block (2), as well as a second anchoring portion (9) acting on an outer surface (4b) of the insulating element (4) out of the hole (7b) formed in the insulating element (4) itself.

9. A proceeding as claimed in one or more of the preceding claims, further comprising the steps of: - providing at least one second block (11) ;

- interposing the insulating element (4) between the first and second blocks (2, 11) ;

- said expansion insert (6) being formed in the cavity (7) made in the first block (2), in the second block (11) and in the insulating element (4) to keep the blocks (2, 11) linked to the insulating element (4) itself.

10. A proceeding as claimed in the preceding claim, wherein following the expanding step, at least one first anchoring portion (8) of the expansion insert (6) is made in at least one inner opening (3a) exhibited by- said first block (2) , as well as at least one second anchoring portion (9) disposed in at least one inner opening (3a) of the second block (11) .

11. A proceeding as claimed in one or more of claims 8 to 10, wherein said anchoring portions (8, 9) are made during the step of distributing the plastic material inside the cavity (7), the cross-section of the elongated body being increased so as to determine a plurality of bulges (6a) defining said anchoring portions (8, 9) .

12. A building product for buildings, comprising:

- at least one first block (2) ;

- at least one insulating element (4) associated with said first block (2) ; and

- engagement means (5) for linking the first block (2) to the insulating element (4) ; characterised in that said engagement means (5) comprises at least one expansion insert (6), injected and solidified in a respective cavity (7) formed in the first block (2) and in said insulating element (4) .

13. A building product as claimed in claim 12, wherein said expansion insert (6) comprises an elongated body having bulges (6a) the width of which in cross-section is greater than that of said cavity (7), for defining respective anchoring portions (8, 9) operating in abutment relationship against said at least one first block (2) and said insulating element (4) .

14. A building product as claimed in claim 12 or 13, wherein said cavity (7) comprises at least one first through hole (7a) formed in said first block (2) and at least one second through hole (7b) formed in said insulating element (4), in the continuation of the first hole (7a) .

15. A building product as claimed in one or more of claims 12 to 14, wherein said expansion insert (6) has at least one first anchoring portion (8) disposed at the first hole (7a) and a second anchoring portion (9) disposed at the second hole (7b) .

16. A building product as claimed in the preceding claim, wherein said first block (2) comprises a body (3) that is at least partly hollow and has at least one inner opening (3a) ; said first anchoring portion (8) extending in said inner opening (3a) and said second anchoring portion (9) being disposed out of the second hole (7b) and extending at least partly on an outer surface (4b) of the insulating element (4) .

17. A building product as claimed in one or more of claims 12 to 16, further comprising at least one second block (11) ; said insulating element (4) being interposed between the first block (2) and the second block (11) .

18. A building product as claimed in the preceding claim, wherein said cavity (7) comprises a third hole (7c) formed in the second block (11) in the extension of said second and first holes (7a, 7c) .

19. A building product as claimed in the preceding claim, wherein said expansion insert (6) comprises at least one first anchoring portion (8) disposed at the first hole (7a) and at least one second anchoring portion (9) disposed at the third hole (7c) .

20. A building product as claimed in claim 8, wherein each block (2, 11) comprises a body (3) that is at least partly hollow and has at least one inner opening (3a); each anchoring portion (8, 9) extending in a respective inner opening (3a) .

21. A building product as claimed in one or more of the preceding claims, wherein said expansion insert (6) is expanded inside the cavity (7).

22. A building product as claimed in one or more of the preceding claims, wherein said engagement means (5) comprises at least two plastically set elements (6) inserted into respective cavities (7) .