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EP0789112B1 - Composite building elements - Google Patents

Composite building elements Download PDF

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Publication number
EP0789112B1
EP0789112B1 EP96120747A EP96120747A EP0789112B1 EP 0789112 B1 EP0789112 B1 EP 0789112B1 EP 96120747 A EP96120747 A EP 96120747A EP 96120747 A EP96120747 A EP 96120747A EP 0789112 B1 EP0789112 B1 EP 0789112B1
Authority
EP
European Patent Office
Prior art keywords
cement mortar
polystyrene foam
layer
mold
outer layer
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Lifetime
Application number
EP96120747A
Other languages
German (de)
French (fr)
Other versions
EP0789112A1 (en
Inventor
Costantino Toffoli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
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 BASF SE filed Critical BASF SE
Publication of EP0789112A1 publication Critical patent/EP0789112A1/en
Application granted granted Critical
Publication of EP0789112B1 publication Critical patent/EP0789112B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material

Definitions

  • the invention relates to composite components made of a core layer made of polystyrene particle foam and at least one top layer made of cement mortar and a method for producing the composite components.
  • DE-A 1 609 631 describes a building board that has one Core of a porous material, e.g. a polystyrene foam, and a layer of gypsum.
  • the building board is manufactured by Applying a gypsum slurry to a board made of the porous material so that the gypsum enters the surface cavities of the board flows.
  • this only results in a superficial, loose connection between core layer and cover layer.
  • the invention was therefore based on the object of composite components to provide, which do not have these disadvantages.
  • the cement mortar is preferably first poured into the mold, then the foam particles are added and the mold closed.
  • the particles expand due to evaporation of the blowing agent still contained in them.
  • These expanding particles exert pressure at the interface on the mortar layer.
  • the liquid cement gives way to this Pressure out by partially in the gusset of the foam particles penetrates so that a smooth transition between the layers A and C arise. At the same time, but a little slower, this happens Sintering of the foam particles and setting of the cement mortar.
  • the inventive method allows considerable time and Cost savings in production without the use of adhesives Need to become.
  • the composite components according to the invention have the following structure: A top layer is included the core layer connected by the intermediate layer. There is a noticeable penetration in the intermediate layer the pre-expanded particles with the cement mortar, penetrated into the gaps between the foam particles is, at a time when the two materials are still were not sintered or solidified. In the subsequent Sintering the foam particles and setting the cement mortar the cement mortar remains in the interlayer in the gusset volume and harden there. This bonding and sintering into each other penetrated materials cause strong consolidation the intermediate layer and a good connection of the core layer with the top layer or the top layers without the use of adhesives.
  • the thickness of the composite components according to the invention can vary Application area fluctuate within wide limits, preferably between 20 and 250 cm, the top layer is preferably between 1 and 20 mm thick.
  • the composite components can have different shapes; e.g. can be used as flat sheets, as corrugated sheets or as roof tiles be trained.
  • the plate-shaped components can in a simple way, e.g. divided by cutting discs or saws or cut to size for easy installation.
  • the polystyrene foam particles can be the usual additives included, e.g. Flame retardants or pigments, as well Cement mortar contains the usual aggregates to make up the composite building elements to impart the desired properties.
  • the components according to the invention can be in different variants are produced, which are within the scope of the invention Move procedure; all details can also be technically equivalent elements are replaced. During the practical Carrying out the procedure can use materials, shapes and sizes be changed as needed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Glass Compositions (AREA)
  • Developing Agents For Electrophotography (AREA)
  • Finishing Walls (AREA)

Abstract

Composite parts, comprising (A) a core layer of polystyrene(PS) particle foam and (C) at least one outer layer of cement mortar, with an interlayer (B) in which the mortar is interspersed in the spaces between the PS foam particles so as to form a continuous transition between layers (A) and (C) and bond these layers together. Also claimed is the production of these parts by (a) filling a mould with liquid cement mortar and PS foam beads with a large inter-bead volume, (b) evacuating the air from the mould and injecting steam, so that the mortar penetrates into the spaces between the beads, the beads expand and sinter together and the mortar sets and solidifies, and (c) cooling and demoulding the product.

Description

Die Erfindung betrifft Verbund-Bauelemente aus einer Kernschicht aus Polystyrol-Partikelschaum und mindestens einer Deckschicht aus Zementmörtel sowie ein Verfahren zur Herstellung der Verbund-Bauelemente.The invention relates to composite components made of a core layer made of polystyrene particle foam and at least one top layer made of cement mortar and a method for producing the composite components.

Im Bereich des Bauwesens ist die Benutzung von Bauelementen bekannt, die aus einer Kernschicht aus Schaumstoff bestehen, an deren Außenflächen Deckschichten aus Zement angebracht sind. Derartige Bauelemente dienen z.B. als Ziegel, Abdeckplatten, Deckenelemente oder Tafeln für die Innen- und Außenverkleidung von Gebäuden. Aufgrund der Kombination von Schaumstoff und Zement weisen solche Bauelemente sowohl eine hohe Isolierwirkung als auch gute mechanische Eigenschaften, insbesondere gute Stoßfestigkeit, auf. Bisher wurden solche Bauelemente folgendermaßen hergestellt:

  • 1. Herstellung der Polystyrolschaum-Schicht durch übliches Versintern vorgeschäumter treibmittelhaltiger Polystyrol-Perlen in einer Form, wobei der in die Form eingeleitete Dampf das Versintern der vorgeschäumten Perlen bewirkt, so daß das vorher zwischen den Perlen vorhandene Zwickelvolumen verschwindet und sich eine kompakter Schaumstoff bildet.
  • 2. Die Schaumstoffschicht wird ein- oder zweiseitig mit einer Zementschicht versehen. Dies ist ein aufwendiges und kompliziertes Verfahren, bei dem Zusatzwerkstoffe, z.B. Klebstoffe verwendet werden müssen, deren Wirkung im Lauf der Zeit nachläßt.
    • In the field of construction, the use of components is known which consist of a core layer made of foam, on the outer surfaces of which top layers of cement are attached. Components of this type are used, for example, as bricks, cover plates, ceiling elements or panels for the interior and exterior cladding of buildings. Due to the combination of foam and cement, such components have both a high insulating effect and good mechanical properties, in particular good shock resistance. So far, such components have been manufactured as follows:
  • 1. Production of the polystyrene foam layer by conventional sintering of foamed propellant-containing polystyrene beads in a mold, the steam introduced into the mold causing the pre-foamed beads to sinter, so that the gusset volume previously between the beads disappears and a compact foam is formed.
  • 2. The foam layer is provided on one or two sides with a cement layer. This is a complex and complicated process in which filler materials, for example adhesives, have to be used, the effect of which wears off over time.

    • In der DE-A 1 609 631 ist eine Bauplatte beschrieben, die einen Kern aus einem porigen Material, z.B. einem Polystyrolschaum, und einer Gipsschicht umfaßt. Die Bauplatte wird hergestellt durch Aufbringen eines Gipsbreis auf eine Tafel aus dem porigen Material, so daß der Gips in die Oberflächenhöhlungen der Tafel fließt. Dies ergibt aber nur eine oberflächliche, lose Verbindung zwischen Kernschicht und Deckschicht.DE-A 1 609 631 describes a building board that has one Core of a porous material, e.g. a polystyrene foam, and a layer of gypsum. The building board is manufactured by Applying a gypsum slurry to a board made of the porous material so that the gypsum enters the surface cavities of the board flows. However, this only results in a superficial, loose connection between core layer and cover layer.

    Der Erfindung lag also die Aufgabe zugrunde, Verbund-Bauelemente bereitzustellen, die diese Nachteile nicht aufweisen.The invention was therefore based on the object of composite components to provide, which do not have these disadvantages.

    Diese Aufgabe wird durch die erfindungsgemäßen Verbund-Bauelemente gelöst.This object is achieved by the composite components according to the invention solved.

    Die Herstellung der Verbund-Bauelemente erfolgt dadurch, daß man

  • a) flüssigen Zementmörtel und Polystyrol-Schaumpartikel mit großem Zwickelvolumen in eine Form einfüllt,
  • b) Luft aus der Form absaugt und Dampf in die Form einleitet, wobei an der Grenzfläche Zementmörtel in die Zwickel der Polystyrol-Schaumpartikel eindringt, die Schaumpartikel weiter expandieren und miteinander versintern und der Zementmörtel abbindet und sich verfestigt zur Deckschicht und
  • c) das Verbundbauelement abkühlt und aus der Form entnimmt.
    • The manufacture of the composite components takes place in that one
  • a) pouring liquid cement mortar and polystyrene foam particles with a large gusset volume into a mold,
  • b) sucks air out of the mold and introduces steam into the mold, cement mortar penetrating into the gusset of the polystyrene foam particles at the interface, the foam particles expand further and sinter together and the cement mortar sets and solidifies to the top layer and
  • c) the composite component cools and removes it from the mold.

    • Dabei wird vorzugsweise zuerst der Zementmörtel in die Form eingefüllt, dann werden die Schaumpartikel zugegeben und die Form geschlossen. Beim Einleiten des Dampfes expandieren die Partikel infolge Verdampfens des in ihnen noch enthaltenen Treibmittels. An der Grenzfläche üben diese expandierenden Partikel einen Druck auf die Mörtelschicht aus. Der flüssige Zement weicht diesem Druck aus, indem er teilweise in die Zwickel der Schaumpartikel eindringt, so daß ein fließender Übergang zwischen den Schichten A und C entsteht. Gleichzeitig, aber etwas langsamer, erfolgt das Versintern der Schaumpartikel und das Abbinden des Zementmörtels.The cement mortar is preferably first poured into the mold, then the foam particles are added and the mold closed. When the steam is introduced, the particles expand due to evaporation of the blowing agent still contained in them. These expanding particles exert pressure at the interface on the mortar layer. The liquid cement gives way to this Pressure out by partially in the gusset of the foam particles penetrates so that a smooth transition between the layers A and C arise. At the same time, but a little slower, this happens Sintering of the foam particles and setting of the cement mortar.

    Dabei werden Verbund-Bauelemente erhalten, die folgende Merkmale aufweisen:

    • eine Kernschicht aus Polystyrol-Partikelschaum ist verbunden mit mindestens einer Deckschicht aus Zementmörtel,
    • gute Dauerhaftigkeit und gute Gebrauchseigenschaften.
    Composite components are obtained which have the following features:
    • a core layer made of polystyrene particle foam is connected to at least one cover layer made of cement mortar,
    • good durability and good usage properties.

    Das erfindungsgemäße Verfahren ermöglicht erhebliche Zeit- und Kostenersparnisse in der Produktion, ohne daß Klebemittel eingesetzt werden müssen.The inventive method allows considerable time and Cost savings in production without the use of adhesives Need to become.

    Die erfindungsgemäßen Verbund - Bauelemente haben folgenden Aufbau : Eine Deckschicht ist mit der Kernschicht durch die Zwischenschicht verbunden. In der Zwischenschicht liegt eine erchebliche Durchdrin- gung der vorgeschäumten Partikel mit dem Zementmörtel vor, der in die zwischen den Schaumpartikel vorhandenen Lücken eingedrungen ist, zu einem Zeitpunkt als die beiden Materialien noch nicht versintert bzw. verfestigt waren. Bei dem anschließenden Versintern der Schaumpartikel und dem Abbinden des Zementmörtels verbleibt der Zementmörtel in der Zwischenschicht im Zwickelvolumen und erhärtet dort. Dieses Abbinden und Versintern ineinander eingedrungener Materialien bewirkt eine starke Verfestigung der Zwischenschicht und eine gute Verbindung der Kernschicht mit der Deckschicht bzw. den Deckschichten ohne Anwendung von Klebemitteln. The composite components according to the invention have the following structure: A top layer is included the core layer connected by the intermediate layer. There is a noticeable penetration in the intermediate layer the pre-expanded particles with the cement mortar, penetrated into the gaps between the foam particles is, at a time when the two materials are still were not sintered or solidified. In the subsequent Sintering the foam particles and setting the cement mortar the cement mortar remains in the interlayer in the gusset volume and harden there. This bonding and sintering into each other penetrated materials cause strong consolidation the intermediate layer and a good connection of the core layer with the top layer or the top layers without the use of adhesives.

    Die Dicke der erfindungsgemäßen Verbund-Bauelemente kann je nach Anwendungsgebiet in weiten Grenzen schwanken, vorzugsweise zwischen 20 und 250 cm, die Deckschicht ist bevorzugt zwischen 1 und 20 mm dick.The thickness of the composite components according to the invention can vary Application area fluctuate within wide limits, preferably between 20 and 250 cm, the top layer is preferably between 1 and 20 mm thick.

    Die Verbund-Bauelemente können verschiedenartig geformt sein; z.B. können sie als flache Tafeln, als Wellplatten oder als Dachziegel ausgebildet sein. Die plattenförmigen Bauelemente können auf einfache Weise, z.B. durch Trennscheiben oder Sägen geteilt oder zurechtgeschnitten werden um einen einfachen Einbau zu ermöglichen.The composite components can have different shapes; e.g. can be used as flat sheets, as corrugated sheets or as roof tiles be trained. The plate-shaped components can in a simple way, e.g. divided by cutting discs or saws or cut to size for easy installation.

    Die Polystyrol-Schaumpartikel können die üblichen Zusatzstoffe enthalten, z.B. Flammschutzmittel oder Pigmente, ebenso kann der Zementmörtel die üblichen Zuschlagstoffe enthalten, um den Verbund-Bauelementen die gewünschten Eigenschaften zu verleihen.The polystyrene foam particles can be the usual additives included, e.g. Flame retardants or pigments, as well Cement mortar contains the usual aggregates to make up the composite building elements to impart the desired properties.

    Die erfindungsgemäßen Bauelemente können in verschiedenen Varianten hergestellt werden, die sich im Rahmen des erfindungsgemäßen Verfahrens bewegen; alle Details können außerdem durch technisch gleichwertige Elemente ersetzt werden. Während der praktischen Durchführung des Verfahrens können Materialien, Formen und Größen je nach Bedarf geändert werden.The components according to the invention can be in different variants are produced, which are within the scope of the invention Move procedure; all details can also be technically equivalent elements are replaced. During the practical Carrying out the procedure can use materials, shapes and sizes be changed as needed.

    Claims (3)

    1. A composite construction component comprising a core layer of molded polystyrene foam and at least one outer layer of cement mortar, wherein, in an intermediate layer, cement mortar has become inserted to the interstitial volume between the polystyrene foam beads and the two materials have penetrated one another to give a gradual transition between the core layer and the outer layer and to produce bonding between the core layer and the outer layer.
    2. A process for producing a composite construction component comprising a core layer of molded polystyrene foam and at least one outer layer of cement mortar, as claimed in claim 1, which comprises
      a) charging a mold with liquid cement mortar and polystyrene foam beads with large interstitial volume,
      b) extracting air from the mold and passing steam into the mold, and cement mortar penetrates into the interstices between the polystyrene foam beads at the interface, the foam beads expand further and sinter with one another, and the cement mortar sets to form an intermediate layer which consolidates to the outer layer, and
      c) cooling the composite construction component and removing the same from the mold.
    3. A process as claimed in claim 2, wherein the setting of the cement mortar and the sintering of the polystyrene foam beads take place simultaneously.
    EP96120747A 1996-02-07 1996-12-23 Composite building elements Expired - Lifetime EP0789112B1 (en)

    Applications Claiming Priority (2)

    Application Number Priority Date Filing Date Title
    ITMN960005 1996-02-07
    IT96MN000005A IT1287722B1 (en) 1996-02-07 1996-02-07 MANUFACTURE COMPOSED OF A LAYER OF EXPANDED POLYSTYRENE AND AT LEAST ONE LAYER OF CEMENT CONCRETE AND PROCEDURE TO OBTAIN THE

    Publications (2)

    Publication Number Publication Date
    EP0789112A1 EP0789112A1 (en) 1997-08-13
    EP0789112B1 true EP0789112B1 (en) 2001-04-04

    Family

    ID=11384563

    Family Applications (1)

    Application Number Title Priority Date Filing Date
    EP96120747A Expired - Lifetime EP0789112B1 (en) 1996-02-07 1996-12-23 Composite building elements

    Country Status (4)

    Country Link
    EP (1) EP0789112B1 (en)
    AT (1) ATE200331T1 (en)
    DE (1) DE59606720D1 (en)
    IT (1) IT1287722B1 (en)

    Families Citing this family (2)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    DE10007775A1 (en) * 2000-02-14 2001-08-16 Wki Isoliertechnik Gmbh Berlin Heat insulation plate of EPS/XPS has an exterior coating of water vapor-permeable, solid, frost- and dust-stable mineral material
    WO2016041559A1 (en) * 2014-09-15 2016-03-24 Thörngren Pontus Petter A building wall and a method for manufacture

    Family Cites Families (3)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    GB1133035A (en) * 1965-06-24 1968-11-06 Elischer Julius William Improved building board
    FR1506460A (en) * 1966-11-03 1967-12-22 Saint Gobain Construction materials
    CH596404A5 (en) * 1976-07-22 1978-03-15 Btr Materiaux Sa

    Also Published As

    Publication number Publication date
    DE59606720D1 (en) 2001-05-10
    ATE200331T1 (en) 2001-04-15
    EP0789112A1 (en) 1997-08-13
    ITMN960005A1 (en) 1997-08-07
    IT1287722B1 (en) 1998-08-18

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