WO2013030391A1

WO2013030391A1 - A wall of a building, method to construct such a wall and element for use in the wall and said method

Info

Publication number: WO2013030391A1
Application number: PCT/EP2012/067045
Authority: WO
Inventors: Erwin Joseph Maria MOMBARG; Albert Antonie Johan BLANKVOORT
Original assignee: Mombarg Erwin Joseph Maria; Blankvoort Albert Antonie Johan
Priority date: 2011-09-02
Filing date: 2012-09-02
Publication date: 2013-03-07

Abstract

The invention pertains to a wall 1 of a building comprising an inner wall 2, adjacent to said inner wall a layer of insulation material 3, and at a distance 4 from the insulation material an outer wall 5 for protecting the insulation material and inner wall against environmental impact, the said distance allowing a free flow of air along the insulation material, the outer wall comprising multiple separate building blocks 6 having a front surface 7 and a back surface 8, the back surface facing the insulation material, wherein the outer wall is comprised of a self-supporting frame 10 to which frame the building blocks are operatively connected using the back surface of each block for establishing the connection, such that each block is in hanging engagement with the frame, the front surface of each block facing the environment. The invention also pertains to a method to construct such a wall and to a building element for use in constructing said wall.

Description

A WALL OF A BUILDING, METHOD TO CONSTRUCT SUCH A WALL AND

ELEMENT FOR USE IN THE WALL AND SAID METHOD

The invention pertains to a wall of a building comprising an inner wall, adjacent to said inner wall a layer of insulation material, and at a distance from the insulation material an outer wall for protecting the insulation material and inner wall against environmental impact, the said distance allowing a free flow of air along the insulation material, the outer wall comprising multiple separate building blocks having a front surface and a back surface, the back surface facing the insulation material. The invention also pertains to a method to construct such a wall and to an element for use in the wall or the said method.

Background art In the art it is commonly known to construct a so called cavity wall, by first forming an inner wall (also known as inner leave or inner skin) which typically (but not necessarily) is the basic part of the ultimate wall of the building to be constructed. For insulation purposes, a layer of insulation material is placed against the inner leave and fixed to it. Then an outer wall (also known as outer leave or outer skin) is build in front of the insulation material out of multiple separate building blocks, for example by traditional brick laying. The outer wall typically has several functions to fulfil. Firstly, it should protect the insulation material and inner wall against environmental impact such as rain, hail, snow, direct sunlight etc. Next to this, the front surface of the outer leave should provide nice aesthetics, suiting the purpose and charisma of the building. A very important feature of this type of wall is the presence of an open space between the back (inner) surface of the outer leave and the insulation material, i.e. a space allowing a free flow of air along the insulation material. This free flow of air is absolutely necessary to prevent that the insulation material becomes damp and ultimately wet, which may lead to rotting of this material and ultimately to a wet inner leave.

Modern day buildings have to meet such stringent energy consumption demands that the thickness of the layer of insulation material is considerable larger than ten to twenty years ago, ultimately leading to a thicker wall. This is generally regarded as

disadvantageous since it increases the footprint of a building. This can be partly compensated by decreasing the distance between the outer leave and the layer of insulation material. However, the free flow of air will be hampered this way, ultimately increasing the chance of the insulation material or even inner leave to become wet. Therefore, it is often accepted that the footprint of a building has to be increased when insulation demands are more stringent.

Summary of the invention

It is an object of the invention to mitigate the prior art disadvantages. To this end wall has been devised wherein the outer wall is comprised of (i.e. includes) a self-supporting frame to which frame the building blocks are operatively connected using the back surface of each block for establishing the connection, such that each block is in hanging engagement with the frame, the front surface of each block facing the environment.

In prior art techniques, the outer leave is assembled by placing the building blocks on top of each other, interconnecting the blocks for example by notches (dry), mortar or glue, thus typically using the lateral surfaces for establishing the ultimate strength of the wall. Inherently, the outer leave thus becomes more or less "closed", i.e. it does not allow air to pass freely through it. Therefore, openings are made here and there for obtaining sufficient ventilation capacity. With the present invention, the ultimate strength of the wall comes about by using a self- supporting frame. To this frame, the building blocks are connected using their back surfaces (which may concomitantly increase the strength of the wall). This way, each building block is in hanging engagement with the frame. With this type of construction there is no longer a need of having building bocks rest upon each other with their lateral surfaces, and thus open spaces may be available along the complete circumference of each building block. This may significantly increase the ventilation capacity of the outer leave, which allows the distance between the outer leave and the layer of insulation material to be minimal. It is noted that the building blocks need not be connected to the frame directly. It may for example be that a frame consisting of metal beams is used, the frame being provided with a membrane, and the blocks being connected on the membrane.

The invention is also embodied in amethod to construct a wall of a building comprising the steps of placing an inner wall, placing a layer of insulation material adjacent the inner wall, placing an outer wall for protecting the insulation material and inner wall against environmental impact at a predetermined distance from the insulation material, the outer wall comprising multiple separate building blocks having a front surface and a back surface, the back surface facing the insulation material, wherein the outer wall is comprised of a self-supporting frame to which frame the building blocks are operatively connected by fastening the back surface of each block to the frame, such that each block is in hanging engagement with the said frame, the front surface of each block facing the environment.

Also, the invention is embodied in a building element suitable for use in a wall and method as described supra, the element comprising a self-supporting frame to which frame multiple separate building blocks are operatively connected, each building block having a front surface to face the environment and a back surface, the operative connection being established by using the back surface of each block to fasten each block to the frame, such that each block is in hanging engagement with the said frame.

Definitions

A block is a substantially rectangular three dimensional element, either massive or hollow, that can be readily placed in an upright position on a ground surface without needing any support, as opposed to e.g. finishing elements such as tiles, glass plates, plasterboard and other board material. A block has a minimum width of a 15 mm, typically 2 to 10 cm, in particular 4 to 10 cm. A non-compliant building block is an element suitable to construct an outer wall of a building, made from a material that is rigid in the sense that it cannot be readily nailed to a support. Typical examples of non-compliant building blocks are bricks, concrete blocks, stones (such as marl, bluestone, freestone, granite, ashlar etc.), as opposed to compliant building blocks made for example from wood, plastic, rubber etc.

A frame is an open construction that allows air to freely pass through in a direction perpendicular to a plane in which the frame extends. A frame typically consist of multiple interconnected beams having openings between the beams, but may for example also consist of a perforated plate, a rack of interconnected wires (a wire rack), a network of fibres (woven or non-woven) etc.

An adhesive is any material capable of fastening two other materials together by means of surface attachment. Adhesives are also known as e.g. "glue", "mucilage" and

"mastic". Although the term adhesive is typically used for polymer based glues, it includes inorganic materials such as portland cement and solders.

A mesh is a grid providing openings in between supporting beams, a beam being an elongated supporting element such as e.g. a shaft, a (e.g. H-, U-, T-, J-, L- ΟΓ Ω-) profiled ribbon, wire or hardened (bundle of) fibers.

Embodiments of the invention

In an embodiment, the blocks are of stone or ceramic material. It has appeared that such blocks are ideally suitable for constituting an outer leave of a wall, given their inherent rigidity and mechanical strength. Surprisingly, it has been found that such dense, heavy blocks can be connected in hanging engagement with a frame.

Concomitant advantage is that such blocks may give the impression of traditional masonry. In another embodiment, each block is connected by an adhesive that is present between the back surface of the block and the frame. An adhesive has been found to be suitable for application in the present invention. It has the advantage above traditional fasteners such as screws, nails, clamps and other fasteners that it is very easy to apply, and gives great freedom in the building process. Preferred adhesives are the organic, often polymeric adhesives, optionally providing chemical reaction after application to increase bonding strength.

In yet another embodiment the blocks do not touch or overlap each other in a vertical direction. It is known in traditional building techniques, mainly techniques wherein planks or other board material is used (being remote from the presently used building blocks) that building elements overlap in vertical direction to increase the resistance of the outer wall against environmental impact. It was found that such overlap can be dispensed with in the present invention, thereby allowing a maximum open space between neighbouring building blocks and hence leading to maximum ventilation capacity.

In still another embodiment there is a space between neighbouring blocks that allows air to freely pass through the outer wall from the front surface to the back surface. The hanging engagement takes the need away for building blocks to rest upon each other, and or to mate laterally. Therefore, when using the present invention an open space may be present between each pair of neighbouring building blocks, thereby substantially improving the free flow of air through the outer leave, into the open space between the outer leave and the insulation material. Still, in a further embodiment, part of the space is filled with a filler material, e.g. for aesthetic reasons or for improving the ultimate strength of the wall.

In an embodiment the frame comprises multiple substantially parallel beams to which the blocks are connected. With multiple beams, for example hollow shafts or profiled ribbons, a very strong yet open construction can be made. The beams can be used for connecting the building blocks to the frame. This way, an inexpensive, but mechanically strong wall can be created that allows a free flow of air through the outer leave into the space between the outer leave and the layer of insulation material.

In another embodiment, the frame comprises a mesh, i.e. a network of wire-like beams having openings in between the beams. A mesh allows that a light but strong

construction can be made having sites for connecting the building blocks evenly distributed over the area of the outer wall. In a further embodiment the mesh is a wire rack. A wire rack can be easily made and also allows the mesh to have a curved surface. With prior art brick-laying like techniques, it is hard to obtain stable curved surfaces. With the new method, when a curved frame is made having sufficient strength, the building blocks can be simple connected to that frame to form a curved outer leave.

In an embodiment of the building method of the invention the outer wall is assembled at a site remote from the site where the wall of the building is constructed, and transported to the building site for constructing the wall. In this so called pre-fab method, the outer wall is assembled at a dedicated site, preferably in-house, not influenced by

environmental conditions. An additional advantage of assembling at a site remote from the building site is that the outer wall can be assembled lying in a substantial horizontal configuration which allows easier assembly of the building blocks and frame, in particular when an adhesive is being used to connect the blocks to the frame. In a further embodiment the outer wall is assembled after longitudinal dimensions of the placed inner wall have been established. It was recognised that the dimensions of the inner wall often are not exactly the same as predetermined by an architect. With prior art building techniques, the end size of the outer wall is often adapted to the size of the inner wall by cutting some (typically the outermost) building blocks to the required size. Apart from the fact that this is aesthetically disadvantageous it costs labour time. With the current invention, since the building blocks do not interact but are connected individually to the frame, the longitudinal sizes of the outer wall can be adapted by simply adapting the lateral space between the blocks, without the need to cut all outermost blocks.

The invention will be further explained based on the following figures and examples.

Figure 1 schematically shows a perspective view of a wall according to the invention. Figure 2 shows a top view of the wall according to figure 1 .

Figure 3 schematically shows a perspective view of another embodiment of the wall according to the invention, the wall comprising a prefabricated building element according to the invention.

Figure 4 shows a detailed front view of part of the outer leave of a wall according to the invention.

Example 1 describes a first example of building a wall according to the invention.

Example 2 describes a second example of building a wall according to the invention.

Figure 1

Figure 1 schematically shows a perspective view of a wall 1 according to the invention. The wall is comprised of an inner leave (or inner wall) 2, in this case a prefabricated concrete element, against which inner leave 2 a layer of glass fibre insulation material 3 is fixed. At a distance 4 from this layer of insulation material (see figure 2 for a more clear view of this distance 4), the outer leave (outer wall) 5 is situated. This outer leave comprises multiple parallel frame parts 10, 10' and 10". These frame parts are connected to the inner leave using metal ties 20 (in another embodiment, the connection of the frame parts allows a variable horizontal positioning of the beams). Together, the frame parts form a self-supporting frame for supporting the building blocks 6 of the outer leave. In this embodiment, the building blocks are elongated blocks of blue stone, calibrated to a predetermined height and length. The depth of each stone is varies a few millimetres (1 -4) from the predetermined mean of about 8 cm. Each building block 6 is glued to a corresponding frame part 10 using the adhesive Tec7 available from Novatech, Olen, Belgium (an adequate alternative adhesive is e.g. Rock7 of the same company). This way the building blocks do not touch each other but are in true hanging engagement with the frame. Between each pair of building blocks there is a space 12 (not indicated in figure 1 , see figure 4 for an indication of the space), allowing a free flow of air through the outer leave into the space between the layer of insulation material and the outer leave. This way, there is a very significant ventilation along the insulation material, even though the distance 4 itself is rather small.

It is noted that in an alternative embodiment, the frame parts are at least partly sunk into the layer of insulation material in order to decrease the total thickness of the wall.

Figure 2

Figure 2 shows a top view of the wall 1 according to figure 1. In this top view the inner wall 2 and layer of insulation material 3 can be clearly distinguished. The distance 4 between this layer of insulation material 3 and the outer leave 5 allows air to freely flow along the insulation material. The outer leave 5 is comprised of the frame parts 10, 10' and 10", connected to the inner leave using ties 20. Of each building block 6, the front surface 7 and back surface 8 can be distinguished.

Figure 3

Figure 3 schematically shows a perspective view of another embodiment of the wall according to the invention, the wall comprising a prefabricated building element 200 according to the invention. The inner wall 2 and insulation layer 3 are equal to the wall and layer as depicted in figures 1 and 2. The prefabricated building element 200 comprises a mesh 101 , which mesh in this case is a perforated self-supporting plate. The plate is connected to frame 10 comprising beams 100. The building blocks 6 are adhered to the perforated plate 101 using the same adhesive as mentioned in connection with figure 1 . This plate with connected building blocks can be assembled at a site remote from the site where the wall is built, having measures exactly adopted to the size of the inner wall.

Figure 4

Figure 4 shows a detailed front view of part of the outer leave of a wall according to the invention. In this detailed view, the space 12 between each pair of neighbouring building blocks 6, the space providing openings of about 3-4 mm in height. In this embodiment, there are horizontal and vertical openings between the building blocks. Near the end of each pair of neighbouring building blocks, there is a filler material 15 present in the openings. This material improving the overall mechanical constitution of the outer leave. Still, since the connection of the building blocks to become a mechanical part of the outer leave substantially arises from the adhesive between the back surface of the blocks and the beams 10, the blocks are regarded as being in hanging engagement with the frame in the sense of the present invention.

Example 1

Example 1 describes a first example of building a wall according to the invention, this example being given in connection with figure 1 . In this embodiment, a wall is constructed by firstly placing an inner leave 2 and a layer of insulation material 3 adjacent this wall in line with commonly applied building techniques. Then, an outer wall is placed as follows: firstly frame parts 10 are connected to the inner wall so as to form a self-supporting frame. Then multiple separate building blocks 6 are each adhered to a frame part, using an adhesive that connects the back surface of each building block to a respective frame part. The blocks are not placed on top of each other but have a space between them in vertical direction. This way, each block is in hanging engagement with the frame. When all blocks are connected, part of the horizontal spaces is filled with a filler material in line with figure 4.

Example 2

In this example a second embodiment of a method according to the invention is described, this method being exemplified in connection with figure 3. As explained supra, the outer wall 5 is assembled at a site remote from the site where the wall of the building is constructed. At this remote site, the building blocks are each adhered to the self-supporting perforated plate 101 (which plate is regarded as a self-supporting frame in the sense of the invention) to form building element 200. However, before this element 200 is formed, at the site where the building is constructed the inner wall 2 and insulation material are placed. To this inner wall, beams 100 are connected. These beams together form a frame to which a further element can be connected. After taking the longitudinal dimensions (width and height) of the placed inner wall, the building element 200 is made having corresponding dimensions. By varying either the size of the building blocks and/or the width of the space between each pair of neighbouring blocks, a building element is created that exactly fits the longitudinal measures of the inner wall. Element 200 is then transported to the building site and connected to the beams 100. Thereafter, further processes can be applied to finish the mechanical and aesthetical properties of the wall 1 .

Claims

1 . Wall (1 ) of a building comprising an inner wall (2), adjacent to said inner wall a layer of insulation material (3), and at a distance (4) from the insulation material an outer wall (5) for protecting the insulation material and inner wall against environmental impact, the said distance allowing a free flow of air along the insulation material, the outer wall comprising multiple separate building blocks (6) having a front surface (7) and a back surface (8), the back surface facing the insulation material, characterised in that the outer wall is comprised of a self-supporting frame (10, 101 ) to which frame the building blocks are operatively connected using the back surface of each block for establishing the connection, such that each block is in hanging engagement with the frame, the front surface of each block facing the environment.

2. A wall according to claim 1 , characterised in that the blocks are of stone or ceramic material.

3. A wall according to any of the preceding claims, characterised in that each block is connected by an adhesive that is present between the back surface of the block and the frame.

4. A wall according to any of the preceding claims, characterised in that the blocks do not touch or overlap each other in a vertical direction.

5. A wall according to any of the preceding claims, characterised in that there is a space (12) between neighbouring blocks that allows air to freely pass through the outer wall from the front surface to the back surface.

6. A wall according to claim 5, characterised in that part of the space is filled with a filler material (15).

7. A wall according to any of the preceding claims, characterised in that the frame comprises multiple substantially parallel beams (10, 10', 10", 100) to which the blocks are connected.

8. A wall according to any of the claims 1 to 7, characterised in that the frame comprises a mesh (101 ).

9. A wall according to claim 8, characterised in that the mesh is a wire rack.

10. A wall according to any of the claims 8 or 9, characterised in the mesh has a curved surface.

1 1. A method to construct a wall (1 ) of a building comprising the steps of: - placing an inner wall (2),

- placing a layer of insulation material (3) adjacent the inner wall,

- placing an outer wall (5) for protecting the insulation material and inner wall against environmental impact at a predetermined distance from the insulation material, the outer wall comprising multiple separate building blocks (6) having a front surface (7) and a back surface (8), the back surface facing the insulation material, characterised in that the outer wall is comprised of a self-supporting frame (10, 101 ) to which frame the building blocks are operatively connected by fastening the back surface of each block to the frame, such that each block is in hanging engagement with the said frame, the front surface of each block facing the environment.

12. A method according to claim 1 1 , characterised in that the outer wall is assembled at a site remote from the site where the wall of the building is constructed, and transported to the building site for constructing the wall.

13. A method according to claim 12, characterised in that the outer wall is assembled after longitudinal dimensions of the placed inner wall have been established.

14. Building element (200) suitable for use in a wall (1 ) according to any of the claims 1 to 10 or a method according to any of the claims 1 1 to 13, the element comprising a self-supporting frame (10, 101 ) to which frame multiple separate building blocks (6) are operatively connected, each building block having a front surface(7) to face the environment and a back surface (8), the operative connection being established by using the back surface of each block to fasten each block to the frame, such that each block is in hanging engagement with the said frame.

15. Building element according to claim 14, characterised in that the blocks are connected to the frame with an adhesive.