WO2011156828A1 - Procédé de fabrication d'un corps composite et corps composites fabriqués par ce procédé - Google Patents

Procédé de fabrication d'un corps composite et corps composites fabriqués par ce procédé Download PDF

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Publication number
WO2011156828A1
WO2011156828A1 PCT/AT2011/000265 AT2011000265W WO2011156828A1 WO 2011156828 A1 WO2011156828 A1 WO 2011156828A1 AT 2011000265 W AT2011000265 W AT 2011000265W WO 2011156828 A1 WO2011156828 A1 WO 2011156828A1
Authority
WO
WIPO (PCT)
Prior art keywords
mass
mineral
composite
partial
body part
Prior art date
Application number
PCT/AT2011/000265
Other languages
German (de)
English (en)
Inventor
Michael Schmid
Original Assignee
Geolyth Mineral Technologie Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Geolyth Mineral Technologie Gmbh filed Critical Geolyth Mineral Technologie Gmbh
Priority to DE212011100109U priority Critical patent/DE212011100109U1/de
Publication of WO2011156828A1 publication Critical patent/WO2011156828A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00637—Uses not provided for elsewhere in C04B2111/00 as glue or binder for uniting building or structural materials

Definitions

  • the invention relates to a method for producing a composite body and composite bodies, which are produced according to this method.
  • 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).
  • 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.
  • 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 nachCumen, 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.
  • a granulated bed of foamed siliceous material perlite, obsidian
  • water and a binder based on cement or lime perlite, obsidian
  • 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.
  • 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.
  • the newly created composite body should be better, namely faster and more flexible to produce.
  • 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.
  • 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.
  • 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.
  • 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.
  • the self-curing formulation is formed from a hydraulically setting binder, a pozzolanic setting binder and a sulfate.
  • 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.
  • 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.
  • the sulfate component is preferably selected from a group comprising calcium sulfate, ⁇ - or ⁇ -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.
  • 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.
  • the formulation may additionally contain SiO 2 particles in a proportion of not more than 10 parts by weight.
  • 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.
  • 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.
  • 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.
  • 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 ⁇ m, preferably not more than 0.3 ⁇ m.
  • 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.
  • 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.
  • 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.
  • the proportion of the thickener is at most 70% of the proportion of the high-performance liquefier.
  • fibers 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.
  • 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.
  • the proportion of the hydrophobizing agent in the formulation can be up to 3 percent by weight, preferably up to 1 percent by weight.
  • 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.
  • the foaming behavior can be better controlled than in the method of direct foaming by means of a blowing agent.
  • the pore size and the pore distribution can thus be better reproducible and influenced in a wider range.
  • 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.
  • a surfactant may be added to the foam component.
  • 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.
  • 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.
  • air entraining agents such as e.g. Alkyl polyglycol ethers, alkyl sulfates or sulfonates, i.a. to improve the stability of the foam.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 Operagroper 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.

Abstract

L'invention concerne un procédé de fabrication d'un corps composite, ainsi que des corps composites fabriqués par ce procédé. Un élément de ce corps composite est constitué d'une matière minérale poreuse. Le matériau d'un deuxième élément présente une plus grande résistance mécanique que celui du premier élément. L'élément minéral poreux est formé par un procédé consistant à préparer en agitant une masse (2) fluide autodurcissante comprenant une formulation minérale, un agent moussant ou gonflant et de l'eau, puis à faire s'écouler et à laisser durcir cette masse (2) dans une cavité délimitée au moins partiellement par la surface de l'élément (1) constitué du matériau présentant la plus grande résistance mécanique. Pour l'opération d'assemblage, de la matière est enlevée de la surface à assembler de l'élément (1), plus résistant, par aspersion avec de l'eau sous une haute pression de pulvérisation et cette surface est mise en contact à l'état prémouillé avec la masse (2).
PCT/AT2011/000265 2010-06-16 2011-06-15 Procédé de fabrication d'un corps composite et corps composites fabriqués par ce procédé WO2011156828A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE212011100109U DE212011100109U1 (de) 2010-06-16 2011-06-15 Verbundkörper

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ATA993/2010 2010-06-16
AT0099310A AT510107A1 (de) 2010-06-16 2010-06-16 Verfahren zur herstellung eines verbundkörpers sowie verbundkörper, welche entsprechend diesem verfahren hergestellt sind

Publications (1)

Publication Number Publication Date
WO2011156828A1 true WO2011156828A1 (fr) 2011-12-22

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Application Number Title Priority Date Filing Date
PCT/AT2011/000265 WO2011156828A1 (fr) 2010-06-16 2011-06-15 Procédé de fabrication d'un corps composite et corps composites fabriqués par ce procédé

Country Status (3)

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AT (1) AT510107A1 (fr)
DE (1) DE212011100109U1 (fr)
WO (1) WO2011156828A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013101840A1 (de) * 2013-02-25 2014-08-28 Knauf Aquapanel Gmbh Körper mit einem Dämmmaterial, Bindmittelmischung zur Erstellung des Dämmmaterials, Verwendung einer Bindemittelmischung zur Erstellung des Dämmmaterials sowie Verfahren zur Herstellung des Körpers

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10155140C1 (de) * 2001-03-29 2003-03-20 Biag Produktions Gmbh & Co Kg Verfahren zur Herstellung einer Bauplatte
FR2915701A1 (fr) * 2007-05-04 2008-11-07 Gypsmix Procede de fabrication d'un element de construction ayant au moins une face resistante au feu.
DE102007040654A1 (de) * 2007-08-27 2009-03-12 Getifix Franchise Gmbh Wärmedämmungsverbundelement
WO2011044605A1 (fr) * 2009-10-15 2011-04-21 Geolyth Mineral Technologie Gmbh Matériau isolant
WO2011044604A1 (fr) * 2009-10-15 2011-04-21 Geolyth Mineral Technologie Gmbh Mousse minérale

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10155140C1 (de) * 2001-03-29 2003-03-20 Biag Produktions Gmbh & Co Kg Verfahren zur Herstellung einer Bauplatte
FR2915701A1 (fr) * 2007-05-04 2008-11-07 Gypsmix Procede de fabrication d'un element de construction ayant au moins une face resistante au feu.
DE102007040654A1 (de) * 2007-08-27 2009-03-12 Getifix Franchise Gmbh Wärmedämmungsverbundelement
WO2011044605A1 (fr) * 2009-10-15 2011-04-21 Geolyth Mineral Technologie Gmbh Matériau isolant
WO2011044604A1 (fr) * 2009-10-15 2011-04-21 Geolyth Mineral Technologie Gmbh Mousse minérale

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013101840A1 (de) * 2013-02-25 2014-08-28 Knauf Aquapanel Gmbh Körper mit einem Dämmmaterial, Bindmittelmischung zur Erstellung des Dämmmaterials, Verwendung einer Bindemittelmischung zur Erstellung des Dämmmaterials sowie Verfahren zur Herstellung des Körpers

Also Published As

Publication number Publication date
AT510107A1 (de) 2012-01-15
DE212011100109U1 (de) 2013-03-04

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