WO2011156828A1

WO2011156828A1 - Method for producing a composite body and composite bodies produced according to said method

Info

Publication number: WO2011156828A1
Application number: PCT/AT2011/000265
Authority: WO
Inventors: Michael Schmid
Original assignee: Geolyth Mineral Technologie Gmbh
Priority date: 2010-06-16
Filing date: 2011-06-15
Publication date: 2011-12-22
Also published as: AT510107A1; DE212011100109U1

Abstract

The invention relates to a method for producing a composite body and to composite bodies produced according to said method. A sub-element of the composite body is produced of a mineral material having pores. The material of the second sub-element has a higher mechanical strength than that of the first sub-element. The mineral sub-element having pores is produced by mixing a flowable, self-curing compound (2) of a mineral formulation with a foaming agent or propellant and water and by allowing said compound (2) to flow into a die the surfaces of contact of which are at least partially formed by the surface of the sub-element (1) of a mechanically stronger material and allowing it to cure therein. For bonding, material is stripped from the surface of the stronger sub-element (1) to be bonded by spraying it with water that is under high spraying pressure and said pre-wetted surface is contacted with the compound (2).

Description

A method for producing a composite body and composite bodies, which are produced according to this method

The invention relates to a method for producing a composite body and composite bodies, which are produced according to this method.

In advantageous applications of the invention, components are produced according to the invention, which are assembled as intended to building parts such as walls, ceilings, floors, columns or girders. These components may be block-shaped (brick), flat (plates) or elongated only in one dimension (carrier).

There is a wealth of proposals to construct components that are intended to be assembled into building parts such as walls, ceilings, floors, columns or beams as a composite body, whereby the required high mechanical strength is usually achieved by means of individual part bodies and good heat insulation through further part bodies.

For example, bricks are formed of composite body, wherein the harder part, the so-called brick body, a fired clay mass or concrete and wherein cavities are filled in this brick base body by a heat-insulating material.

Often, the heat-insulating material is a foamed plastic. The plastic can be filled in liquid form in cavities of the brick base body, and harden there and also let nachschäumen, plastic and brick base stick together. But it is also possible to press "finished" foam plastic body in the cavities of the brick base body and to hold it by elastic pressure and friction, especially for structural-physiological reasons (Diffusion openness) and for reasons of fire protection plastic is often considered in this application as disadvantageous.

The heat-insulating filling of cavities of the brick may also be a mineral material. Typically, a granulated bed of foamed siliceous material (perlite, obsidian) is mixed with water and a binder based on cement or lime, and the flowable mass thus formed is introduced into cavities of the tile base body and allowed to harden. The material is compared to plastic construction physiological and also in terms of fire protection advantageous. The disadvantage is especially the time-consuming connection process with the brick body.

In principle, the same considerations and conclusions as for bricks, also apply to components that are elongated in only one dimension (carrier).

For plate-shaped components similar considerations apply. More often than in the previously discussed components one manufactures these by first making plates from the individual elements and then connecting them later, sometimes only on the construction site.

The object underlying the invention is to form a composite body of at least one porous, mineral part body (which should have a high thermal insulation value) and at least one further part body whose material is mechanically stronger relative to that of the first part body. The composite body should be used, for example, as a component of a load-bearing part of the building.

Compared with known composites that meet these requirements, the newly created composite body should be better, namely faster and more flexible to produce.

In order to solve the problem, it is proposed according to the invention to form the porous, mineral partial body of the composite body. from a mineral, self-curing formulation, a foaming agent or blowing agent and water, a flowable, self-curing mass is stirred by this mass in a still flowable state in a cavity whose boundary surfaces are at least partially formed by surfaces of the body part of mechanically stronger material and allowed to cure in it.

Since the said flowable material is easy to prepare, easy to handle, has a good flowability and can harden quickly (within a few minutes) to green strength in said cavity, the production process is fast and flexible.

The thus formed porous mineral body is very good heat resistance and emits in case of fire, no dangerous substances. The individual materials required for its production are available at low cost.

For the connection of the individual body part of the composite body, there is no need for a separate intermediate layer. If the mechanically stronger partial body likewise consists of a mineral material and has a porous surface, a good adhesion to the still more porous, mineral partial body which forms on it forms itself.

It is also possible to pretreat the surface of the mechanically stronger partial body in an advantageous manner. A very good pretreatment is to spray the surface with a jet of water, as is typically emitted from a high-pressure cleaner at, for example, five bar spray pressure, and thus superficially slightly remove material from it. Still in the wet state, this surface is to be introduced ge ^¬ with said flowable mass in contact.

Of course, a good connection between the part bodies can also be achieved by positive locking, that is, by the fact that surfaces of one part body comprise the other part body or parts thereof. In an advantageous embodiment, the self-curing formulation is formed from a hydraulically setting binder, a pozzolanic setting binder and a sulfate.

Preferably, the hydraulically setting binder of the formulation is formed on the basis of a sulfate aluminate cement. It contains a sulphate component and an aluminum component and is included in the formulation at least 50% by weight.

Preferably, the foam component of the previously blended and stirred with the addition of water to a slurry formulation is mixed in a second mixing stage.

The said hydraulically setting binder causes the porous, mineral body part does not or only very slightly shrink during the hardening. Too much shrinkage - which would occur in many other materials - would cause the porous, mineral sub-body to detach from the mechanically-bearing sub-body, or to break the porous, mineral sub-body.

The proportion of the sulfate-aluminate cement in the formulation is preferably at least 60 parts by weight, in particular at least 70 parts by weight. As a result, the mechanical properties and the insulating properties of the porous, mineral part body are favorably influenced.

The sulfate component is preferably selected from a group comprising calcium sulfate, α- or β-hemihydrate or dihydrate of calcium sulfate, anhydrite, sodium sulfate, iron (II) sulfate, magnesium sulfate and mixtures and derivatives thereof. It will thus hydrate phases are generated during the hardening of the porous, mineral body part, which undergo a phase change over time, the strength increases. The aluminum component is preferably selected from a group comprising aluminum oxide (Al 2 O 3), aluminum hydroxides, aluminum silicates, aluminates and mixtures and derivatives thereof. It can thus be positively influenced the solidification behavior and the setting time of the porous, mineral body part.

The ratio of the sulphate component to the aluminum component can be selected according to one embodiment from a range with a lower limit of 4:10 and an upper limit of 20:30. It is thus achieved that the setting time of the slurry does not take so long that the danger It is that the added foam collapses and thus the porosity of the porous mineral body part is reduced. It is thus simplified by keeping the ratio of the two components in this area, the processing.

In particular, to further improve this behavior, the ratio of the sulfate component to the aluminum component may be selected from a range having a lower limit of 6:12 and an upper limit of 13:22, preferably a lower limit of 10:18 range and an upper one Limit of 12: 24.

To improve the mechanical properties of the porous, mineral part of the body, the formulation may additionally contain SiO 2 particles in a proportion of not more than 10 parts by weight. However, the proportion of SiO 2 particles is preferably not more than 7.5 parts by weight, in particular not more than 7.5 parts by weight.

According to another embodiment variant, the formulation contains special SiO 2 particles in the form of so-called silica fumed. It is a reactive SiO 2 that can improve the fire resistance performance of the porous, mineral sub-body by having a "cooling" effect by consuming energy for reactions In this case, carbon-free SiO 2 particles with a purity of at least 97% are used.

In one embodiment, it is provided that the SiO 2 particles have a BET surface area between 5 m ² / g and 35 m ² / g, in order to increase the reactivity. The SiO 2 particles preferably have a BET surface area between 10 m ² / g and 25 m ² / g, in particular between 16 m ² / g and 20 m ² / g. Preferably, the SiO 2 particles have a particle size of at most 45 pm, wherein in particular the proportion of coarse grain is limited to a maximum of 2% and the remainder of the SiO 2 particles have a particle size of not more than 1 μm, preferably not more than 0.3 μm.

The formulation may further contain at least one so-called high performance plasticizer to influence the rheological behavior of the slurry formed from the formulation, provided that the addition of silica fumed, which also has a liquefying effect due to the spherical shape of the particles, not solely for this purpose is sufficient, the proportion is limited to a maximum of 3 percent by weight. In particular, when silica fumed is included in the formulation, the proportion of the high-performance plasticizer is limited to a maximum of 0.5 percent by weight, preferably at most 0.3 percent by weight.

The high-performance liquefier is preferably a polycarboxylate ether or a derivative thereof in order to be able to reduce the water content of the slurry so that less water is available for setting and thus the desired phases are formed more reliably.

It is also possible that the formulation for stabilizing the slurry and thus for better processability of the slurry at least one thickener is added in a proportion of not more than 0.5 percent by weight. The thickener is preferably added in a proportion of not more than 0.25 percent by weight, in particular not more than 0.02 percent by weight. The thickener is preferred selected from a group comprising hydroxymethylpropylcellulose, methylhydroxyethylcellulose and mixtures and derivatives thereof, since it has been found within the scope of the tests carried out for the invention that these thickeners have better properties with regard to processing, such as rheology, dispersion of the solids, or have the water requirement and the water retention capacity. With regard to the processability of the slurry, it has also been found that improvements occur when the proportion of the thickener is at most 70% of the proportion of the high-performance liquefier.

It is furthermore possible for fibers to be added in a proportion of not more than 3 percent by weight, in particular not more than 1 percent by weight, preferably 0.3 percent by weight, in order to improve the flexural strength of the porous mineral body part. But it can also be used to stabilize the foam component. In addition, e.g. Store cellulose fibers water, which is needed in the setting process, this physically "bound" water is better controlled with respect to the hardening of the mineral foam.

Cellulose fibers can also be used as thickeners.

The fibers preferably have a maximum length of 50 mm, in particular a maximum of 30 mm, and are in particular selected from a group comprising cellulose fibers, basalt fibers, glass fibers, in particular alkali-resistant glass fibers, polypropylene fibers, and mixtures thereof.

Fibers of greater length, that is, for example, with a length between 3 mm and 50 mm, in particular between 3 mm and 30 mm, preferably between 3 mm and 12 mm, the diameter of which is preferably between 13 pm and 25 pm, preferably between 13 pm and 18 pm is added, especially when the bending tensile strength is to be increased.

Fibers up to a length of 0.1 mm, preferably up to 30 pm, and in particular a diameter of up to 2 pm, preferably up to 1.5 μm, however, are preferably added for rheological reasons.

The formulation may be added to improve the rheology at least one processing aid from a group comprising an alkali metal carbonates, alkali metal sulfates, fruit acids, for example as a retarder.

In order to reduce the proportion of sorption moisture in the porous, mineral part of the body and thus to improve the thermal insulation (λ value), it can be provided that at least one hydrophobicizing agent is added, in particular for the mass hydrophobization of the formulation. The proportion of the hydrophobizing agent in the formulation can be up to 3 percent by weight, preferably up to 1 percent by weight.

According to another embodiment of the formulation, it may be provided that these additives are free of aggregates, i. is free of fillers, so contains no non-reactive constituents, whereby the density of the porous mineral body part can be further reduced.

The foam component is preferably formed by a protein foam and / or a surfactant foam. Thus, the foaming behavior can be better controlled than in the method of direct foaming by means of a blowing agent. In particular, the pore size and the pore distribution can thus be better reproducible and influenced in a wider range. Thus, the thermal conductivity or the sound absorption capacity of the porous mineral body part can be better adjusted.

The proportion of foam component per m ^{3 of} slurry is preferably between 30 kg / m ³ and 70 kg / m ³ , in particular between 40 kg / m ³ and 60 kg / m ³ . In this area, particularly good insulating behavior of the porous, mineral part body can be achieved. To stabilize the foam during mixing in the slurry from the formulation with water, a surfactant may be added to the foam component.

According to a preferred embodiment variant, the porous, mineral part body has a pore content of at least 70%, in particular between 80% and 95%. Due to this high proportion of pores not only the insulating behavior per se can be improved, but is thus also a lower density of the porous, mineral body part reachable. In this case, the pores preferably have a diameter of at most 0.5 mm, in particular not more than 0.25 mm or not more than 0.1 mm, on the one hand to achieve a positive insulating behavior and on the other hand to improve the mechanical stability of the porous, mineral body part ,

The foam component may also include air entraining agents, such as e.g. Alkyl polyglycol ethers, alkyl sulfates or sulfonates, i.a. to improve the stability of the foam.

According to one embodiment variant of the method, it is provided that the foam component is added to water and possibly processing aids before addition to the slurry in a foam generator, whereby its processability, in particular the stability of the foam during mixing with the slurry, can be improved. It can be arranged in the device for foaming the foam component, a foam generator, in which a protein mixed with water with a gas, in particular air, is foamed.

The invention is illustrated by means of a drawing.

Fig. 1 shows in schematic form an exemplary arrangement for producing a composite body according to the invention in a vertical sectional view. 1 is on a flat, solid base plate 3, which may be to prevent adhesion, for example, be coated with PTFE or may consist entirely of polyamide, the mechanically fixed part body 1 set up, which may be, for example, a perforated brick as a brick base. This mechanically fixed part body 1, which has approximately prismatic outer contour, has some hollow chambers which extend vertically through it and are open at the top and bottom, wherein the lower openings are closed by the base plate 3.

By a supply 4, which may be formed for example by a tube with a screw conveyor disposed therein, flowable mass 2 is filled from the slurry of the formulation described above and the foam component blended therein in the hollow chambers in the mechanically solid part body 1.

If a sufficient amount of this mass 2 is filled, the supply of further mass 2 is turned off and smoothed the surface of the filled mass by means of a straight bar, the mass 2 is subtracted. As a result, the surface of the mass 2 is flat and flush with the top of the mechanically solid part body 1 is formed.

The mass 2 hardens in the hollow chambers to individual porous, mineral part bodies, which is connected to the mechanically solid part body 1. The rate of curing is dependent on the exact composition of the formulation in the mass 2. In particular, by the proportion of fruit acid, such as citric acid, the curing rate can be influenced. Greening is the mass 2 typically after five to ten minutes. The base plate 3 can therefore be removed after this time without the shape of the consisting of hardening mass 2 and mechanically solid part body 1 composite body still changes. 80 percent of the final strength of the resulting porous, mineral sub-body typically reached after a few hours. The composite body thus formed may typically be a composite thermal insulation brick.

Based on the described basic principle, it is in the field of professional trade to automate individual steps of the production process or even the entire procedure. Therefore, the topic "automation of the manufacturing process" will not be discussed here.

By means of the invention, the high mechanical strength of a first partial body can be combined in the best possible way with the high thermal insulation capability of a very lightweight and therefore very porous and thus forcibly mechanically very impermeable porous mineral partial body. The porous, mineral part of the body can be formed in the described composition with a density lower than 300 kg / m ³ and with a lower thermal conductivity than 0.05 W / mK. The connection of the individual body parts is associated with no disadvantages such as loss of diffusion openness, requirement of adhesive, etc.

The inventive method is also applicable when a mechanically fixed Teilköper is already installed at its place of use, and only there is to be combined with a porous, mineral part body to form a composite body. For this it is only necessary to touch the hardening mass according to FIG. 2 only at the place of use and to fill it into the corresponding cavities. Using a retarder you can mix the mass a little earlier, in a not too far from the place of use to move and similar to ready-mixed concrete transported to the site and fill.

In an advantageous application, one can thus a wall which is formed by a flat frame framework and attached to both sides plasterboard, subsequently with respect to sound and heat insulation, as well as fire resistance and mechanical strength significantly improve by one fills the cavities between the gypsum plasterboard with hardenable mass according to FIG. It is characterized a composite ^¬ body made of plasterboard, truss parts and mineral, foamed material.

In a further advantageous application, for the purpose of thermal building renovation, cavities in ceilings, especially in ceilings to the loft, flat roofs or terraces, in retrospect filled with mass as in Fig. 2.

Claims

claims

1. A method for producing a composite body of at least two partial bodies, wherein a partial body of a mineral, pore-containing substance is formed and wherein the material of the second partial body relative to that of the first partial body has a higher mechanical strength, wherein the mineral, pores having partial body formed is by a flowable, self-curing mass (2) of a mineral formulation, a foaming or blowing agent and water is stirred and by this mass (2) in a cavity whose boundary surfaces at least partially formed by the surface of the body part (1) of mechanically stronger material are allowed to flow in and are allowed to cure in

characterized in that

from the coming into contact with the mass (2) surface of the body part (1) of mechanically stronger material as a pre-treatment for the bonding process with the mass (2), by spraying with water under high spray erosion, material is removed and that with the mass (2) coming into contact surface of the body part (1) of mechanically stronger material in vorbenässtem state with the mass (2) is brought into contact

2. The method according to claim 1, characterized in that the mineral formulation of a hydraulically setting binder, a pozzolanic setting binder and a sulfate is mixed.

3. The method according to claim 1 or claim 2, characterized in that mass (2) is filled in order to form a thermal insulation composite brick in a cavity of a brick base body.

A method according to claim 1 or claim 2, characterized in that mass (2) is filled into a cavity in a building surface.

A method according to claim 4, characterized in that mass (2) is filled in the cavity between two arranged on both sides of a flat frame plasterboard.

Composite body of at least two partial bodies, wherein a partial body consists of a mineral, pore-containing material and wherein the material of the second partial body relative to that of the first partial body has a higher mechanical strength, wherein the mineral, pore-containing body part was formed by a flowable, self-curing mass (2) from a mineral formulation, a foaming agent or propellant and water was stirred and by this mass (2) was introduced into a cavity whose boundary surfaces are at least partially formed by the surface of the body part (1) of mechanically stronger material, and therein was allowed to cure

characterized in that

from the coming into contact with the mass (2) surface of the body part (1) of mechanically stronger material as a pre-treatment for the bonding process with the mass (2), by spraying with water under high spray erosion, material was removed and that with the mass (2) coming into contact surface of the body part (1) of mechanically stronger material in vorbenässtem state with the mass (2) has been brought into contact.

Composite body according to claim 6, characterized in that the mineral formulation consists of a hydraulically setting binder, a pozzolanic setting binder and a sulfate.

8. A composite according to claim 6 or claim 7, characterized in that it is a component which is intended together with similar components to building parts such as walls, ceilings, floors, columns or beams assembled.

9. Composite body according to claim 8, characterized in that it is a composite thermal insulation brick.

10. A composite according to claim 8, characterized in that it is a sandwich plate, wherein the middle layer is formed by the mineral, pore-containing substance.