DE102018000396A1 - Component for a building u.a. - Google Patents

Abstract

The invention relates, inter alia, to a building element (10) for a building (29), in particular in the manner of a prefabricated concrete part, comprising a casing (12), which functions as shuttering (11), of a flexible, e.g. textile, material providing a completely closed and / or closeable interior (13) filled with a foam concrete mass (15).

Description

The invention first relates to a building component according to claim 1.

Building elements, in particular the type of concrete finished parts, or concrete parts, are well known. Here are prepared either at the construction site on site or in a manufacturing plant for precast concrete formwork that provide a cavity that is filled with a liquid concrete mass. After curing, the formwork is removed and the bare concrete part is available to provide a building wall or part of a wall of a building. It is known to provide building side walls, building floor walls, building ceilings or other parts of a building from finished concrete parts. Typical concrete masses have densities of about 2.5 t / m ³ .

Recently, inter alia with the participation of the applicant, foam concrete masses have been developed which have a significantly reduced density compared to conventional concrete compounds.

A distinction is made between aerated concrete and foam concrete.

The present patent application relates exclusively to components and components as well as methods that use or rely on foam concrete masses.

A foam concrete mass within the meaning of the present patent application consists of a mixture of cement paste and foam.

It is therefore first produced cement paste, so cement-stirred with water, with other additives, such as hydroxyapatite or other suitable additives are used. This cement paste is mixed in a first container, or provided there.

Irrespective of the cement paste, foam is provided. The foam is provided, for example, in a foaming device.

The cement paste and the foam are then mixed together in a further process step. This is a foam concrete mass within the meaning of the present patent application.

In contrast to foam concrete masses, aerated concrete masses are also known in the state of the art: these are concrete masses of a substantially conventional type, whereby the cement paste is mixed with gases which lead to pore formation in the concrete.

As far as foam concrete masses are currently used, recourse is made to conventional formwork. For example, foam concrete masses can be manufactured in a factory for the production of parts of buildings, and this are filled into a prepared formwork. After the foam concrete mass has hardened, the formwork is removed. The resulting building part made of hardened foam concrete is then available for use on a construction site.

Alternatively, it is known to cast on site, ie at the construction site, a foam concrete component: For this purpose, a formwork, for. B. using formwork boards, provided, and the shuttering space thus formed, so filled the cavity with the Schaumbetonmasse. After curing, the formwork is removed.

Based on this prior art, the invention has for its object to provide a device which allows a simplified and improved production.

The invention solves this problem with the features of claim 1.

According to the invention, there is provided a building component having an envelope of a flexible material functioning as formwork. The shell provides a completely closed and / or closable interior that is filled with a foam concrete mass.

The shell can z. B. consist of a textile material. For example, woven or knitted fabrics of natural or synthetic fibers or mixtures thereof may be used. The shell can also be permeable to air to a certain extent. In particular, it serves to completely or substantially completely prevent the liquid foam filled into the interior of the shell at an exit.

The sheath can be folded or compressed in the manner of a hose or a bag-shaped structure in a quiescent state or transported. It has an inlet that cooperates with a valve. The inlet and / or the valve are closable. A delivery line for foam concrete masses can be connected to the inlet. With the aid of a pump, the liquid foam concrete mass can be introduced into the interior of the shell. This is advantageously done under a certain pressure, in particular under a minimum pressure. The Filling process is carried out until the shell is completely filled. The envelope of flexible material, after complete filling, has a predetermined spatial form, which corresponds to the envelope contour of the building part to be manufactured.

When the envelope is completely or sufficiently filled with foam concrete mass, the valve is closed and thus the inlet shut off. The liquid foam concrete mass can no longer escape through the inlet, but is trapped in the interior of the shell. The shell filled with foam concrete now has a geometric contour or spatial form that corresponds or can correspond to the contour of the building part to be manufactured. For example, this may be a planar element or a cuboid or even any curved spatial form.

In the case of a cuboid, the device may, for example, a wall, for. B. provide a side wall of a building, or provide a part of a side wall of a building.

Of the invention is also included, if the component provides a total of a building part.

Thus, for example, tent-like accommodations can be provided which have a single common living space, or, in an alternative of the invention, also several rooms or partitions.

After a relatively short time, z. B. after 24 hours, the foam concrete mass is completely cured. Of course, the curing times depend, among other things, on the humidity of the ambient air, and on the ambient temperature. In any case, even after the short curing time, the component to be manufactured has cured to the extent that it is self-supporting.

The shell may remain permanently on the device manufactured in this way.

The component can therefore be manufactured, for example, as follows:

At a construction site, so at the later installation or installation of the building, a shell is provided. This can be transported in a space-saving compressed to the site of the construction site in a simple way.

On site, a foam concrete mass is produced, and the shell filled with it. A filling of the shell can therefore be done at the later installation of the device.

If necessary, the case can also be positioned or fixed in position during filling.

If the component is to form ceiling sections of a building to be manufactured, the shell can be underpinned by supports or support elements until the foam concrete mass has hardened. Other position fixing or positioning are conceivable.

After curing of the foam concrete mass and completed in this way completion of the device such positioning can also be removed if necessary.

The fabricated device has a shell that can remain on the cured foam concrete core. In embodiments of the invention, the sheath can also be removed if necessary, for example, peeled off or torn off, or burned.

Advantageously, however, the flexible sheath is designed such that it acts as a kind of reinforcement. On this reinforcement mortar layers or plaster layers, possibly also layers of paint, for example, in a particularly simple manner can be attached. In embodiments of the invention, low levels of liquid foam concrete mass may escape outwardly through the shell after filling the shell, thus partially coating or wetting the exterior of the shell with the liquid foam concrete mass. If necessary, these portions of the foam concrete mass emerging from the shell can also be smoothed to prevent the subsequent application, for As a color layer to facilitate.

For the purposes of the present invention, foamed concrete masses are understood as meaning those materials which have a density of less than 300 kg / m ³ in the hardened and dried state.

Even today foam concrete masses can be produced which have such low densities, for example in the order of magnitude of between 100 and 200 kg / m ³ .

Ultimately, the density to be achieved depends on the one hand on the aggregates used, on the other hand on the required strength and rigidity of the cured component.

The use of flexible sheaths as a formwork for conventional concrete masses was previously not possible because the forces acting were too large. Only the foamed concrete masses according to the invention to be used with very low densities allow the use of a flexible formwork at all.

The shell may have a single chamber, or be divided into several chambers. It can further be provided that the casing has only one inlet or alternatively several inlets. As is known, for example, from air mattresses, components according to the invention can be provided by using a sleeve which has a plurality of chambers, wherein each chamber is assigned its own inlet or, alternatively, a plurality of its own inlets.

According to the invention, one valve may be associated with each inlet. The valve can be designed to be automatically closing or manually closable. It may also be a simple check valve, which allows a filling, but blocks an exit.

According to one embodiment, the shell has a plurality of chambers, which are separated from each other, and filled with foam concrete masses of different densities.

For example, chambers may be formed in the manner of pipes or hoses, and be filled with foam concrete masses of higher density. Adjacent chambers of the envelope with a larger volume may be filled with foam concrete masses of lower density.

After curing of the different foam concrete masses, the strands of foam concrete mass with higher bulk density in the manner of a strut can provide for a higher strength or rigidity of the component thus formed. For example, thereby a kind of skeleton construction for a component or for a building is possible, wherein the stiffening struts thus formed are an integral part of the shell or the formwork.

For example, low densities can be measured in the range of 50 to 300 kilograms per cubic meter, and densities of 500 to 1,200 kilograms per cubic meter can be considered as a higher foam concrete density.

In the area of the valve, a coupling point is advantageously arranged, which allows a coupling and decoupling of a feed line for conveying the liquid foam concrete mass of the shell. It is provided and covered by the invention, when the liquid foam concrete mass is supplied from the mixing device with the aid of a pump under pressure to the respective valve. Once the corresponding chamber is filled, the delivery line can be decoupled from the valve and, if necessary, coupled with another valve to fill another chamber of the same envelope or other envelope with liquid foam concrete mass.

Depending on the geometry of the interior, provision may also be made for a chamber to have a plurality of different inlets at points remote from one another in order, for example, to ensure uniform filling and homogenous propagation of the liquid foam concrete mass within the interior of the shell.

The sheath may contain fibers or consist of fibers that can withstand particularly high tensile forces, such as glass fibers, carbon fibers, Kevlar fibers, aramid fibers or metal wires.

The invention relates according to a further aspect of a formwork for a foam concrete mass.

The invention has for its object to provide a formwork that allows over the prior art, an improved and simplified production of a building part.

The invention solves this problem with the features of claim 8.

To avoid repetition, reference is made to the previous statements.

Finally, the invention relates to claim 13, a method for producing a component for a building.

The object of the invention is to provide a method by which a component can be produced in a particularly simple manner.

The invention solves this problem with the features of claim 13.

• 1 in einer teilgeschnittenen schematischen Übersichtsdarstellung nach Art eines Blockschaltbildes ein Behältnis mit Zementleim, ein Behältnis mit Schaum, ein Mischbehältnis, eine Förderleitung, eine Pumpe und eine Schalung oder Hülle eines zu fertigenden Bauelementes für ein Gebäude, welches gerade mit einer flüssigen Schaumbetonmasse befüllt wird,
• 2 das ausgehärtete Bauelement der 1 in einer schematischen Schnittdarstellung etwa entlang Schnittlinie II - II in 1,
• 3 in einer teilgeschnittenen schematischen Ansicht ein Ausführungsbeispiel eines Gebäudes, welches aus vier erfindungsgemäßen Bauelementen zusammengesetzt ist bzw. solche Bauelement aufweist, wobei veranschaulicht ist, dass die Bauelemente unter Zuhilfenahme von Befestigungselementen miteinander verbunden sein können,
• 4 in einer teilgeschnittenen schematischen Ansicht ein Ausführungsbeispiel einer Hülle oder Schalung für ein Bauelement mit drei Kammern,
• 5 in einer teilgeschnittenen schematischen Schnittdarstellung ein ausgehärtetes Bauelement der 4 etwa entlang Schnittlinie V - V in 4,
• 6 in einer Darstellung gemäß 5 das Bauelement der 4 entlang Schnittlinie VI - VI in 4,
• 7 ein weiteres Ausführungsbeispiel einer erfindungsgemäßen Schalung oder Hülle für ein Bauelement in einer Darstellung gemäß 4, wobei hier drei getrennte Kammern mit drei voneinander unabhängigen Einlässen und drei Ventilen vorgesehen sind,
• 8 das Bauelement der 7 befüllt mit einer ausgehärteten Schaumbetonmasse, in einer Schnittdarstellung gemäß VII - VII in 7,
• 9 ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Bauelementes bzw. zeltartigen Gebäudes in einer schematischen vereinfachten Ansichtsdarstellung, wobei eine Türausparung vorgesehen ist,
• 10 das Bauelement der 9 in einer schematischen Schnittdarstellung etwa entlang Schnittlinie X - X in 9,
• 11 das Bauelement der 9 und 10 in einer Draufsicht etwa entlang Ansichtspfeil XI in 10,
• 12 ein weiteres Ausführungsbeispiel des Bauelementes in einer Darstellung gemäß 2, wobei angedeutete Schichten auf der Außenseite der Hülle vorgesehen sind, und zwar in Form von Farbschichten, Mörtelschichten oder Putzschichten, und 13 ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Bauelementes in einer Darstellung gemäß 2, wobei zusätzliche innerhalb des Innenraums der Kammern verlaufende Querfasern vorgesehen sind.

Further advantages of the invention will become apparent from the non-cited claims and from the following description of the embodiments illustrated in the figures. Show:

• 1 in a partially sectioned schematic overview in the manner of a block diagram of a container with cement paste, a container with foam, a mixing container, a delivery line, a pump and a formwork or shell of a component to be manufactured for a building, which is being filled with a liquid foam concrete mass,
• 2 the cured component of 1 in a schematic sectional view approximately along section line II - II in 1 .
• 3 in a partially sectioned schematic view of an embodiment of a building, which is composed of four components according to the invention or has such a component, wherein it is illustrated that the components can be connected to each other with the aid of fasteners,
• 4 in a partially sectioned schematic view of an embodiment of a shell or formwork for a device with three chambers,
• 5 in a partially sectioned schematic sectional view of a cured component of 4 approximately along cutting line V - V in 4 .
• 6 in a representation according to 5 the component of 4 along cutting line VI - VI in 4 .
• 7 a further embodiment of a formwork or shell according to the invention for a component in a representation according to 4 , here three separate chambers are provided with three independent inlets and three valves,
• 8th the component of 7 filled with a hardened foam concrete mass, in a sectional view according to VII - VII in 7 .
• 9 a further embodiment of a device according to the invention or tent-like building in a schematic simplified view representation, wherein a door recess is provided,
• 10 the component of 9 in a schematic sectional view approximately along section line X - X in 9 .
• 11 the component of 9 and 10 in a plan view approximately along view arrow XI in 10 .
• 12 a further embodiment of the device in a representation according to 2 , wherein indicated layers are provided on the outside of the shell, in the form of color layers, mortar layers or plaster layers, and 13 a further embodiment of a device according to the invention in a representation according to 2 , wherein additional transverse fibers extending within the interior of the chambers are provided.

Embodiments of the invention are described by way of example in the following description of the figures, also with reference to the drawings. For reasons of clarity, identical or comparable parts or elements or regions with the same reference numerals, sometimes with the addition of small letters, are also referred to - even if different embodiments are involved.

Features which are described only in relation to an embodiment can be provided in the context of the invention in any other embodiment of the invention. Such modified embodiments are - even if they are not shown in the drawings - covered by the invention.

All disclosed features are essential to the invention. In the disclosure of the application, the disclosure content of the associated priority documents (copy of the prior application) and the cited references and the described devices of the prior art are hereby incorporated in full, also for the purpose of one or more features of these documents in one or more Claims of the present application to include.

The component to be manufactured is indicated in the different embodiments of this patent application in the drawings by the reference numeral 10 designated.

The component 10 includes a shell 12 made of a flexible material. This may be, for example, a textile fabric. The case 12 forms a kind of formwork for the liquid foam concrete mass to be absorbed 15 ,

With reference to the embodiment of 1 intended to be the manufacturing process of a component 10 briefly explained as follows:

In a first container is first cement paste 16 mixed or provided. Cement paste is a conventional term that describes a water-enriched cement in a liquid form. In addition to water and cement can in the cement paste 16 also contain other additives, such as hydroxyapatite.

Regardless of the cement paste 16 will foam in another container 17 provided. The foam 17 may be, for example, using foaming agents and / or suitable foaming devices 21 getting produced.

The cement paste 16 and the foam 17 are now separately, about in 1 indicated, separate supply lines a mixing container or a mixing device 19 fed. Here is also an agitator 20 included, which is indicated schematically. The cement paste 16 and foam 17 existing mixture 18 gets through the agitator 20 in the mixing device 19 distributed homogeneously. After mixing, this mixture 18 as foam concrete mass 15 designated.

In a further embodiment, not shown, a foaming device 21 into the mixing device 19 also be integrated.

The liquid foam concrete mass 15 will now be via a support line 38 or over different sections 38a . 38b such a delivery line of the shell 12 fed. 1 indicates an optional advantageous to be provided pump 39 on which the liquid foam concrete mass 15 under a predetermined or predeterminable pressure in the interior 13 the shell 12 brings. The case 12 has an inlet for this purpose 36 on, with the help of a valve 37 can be locked. The valve 37 can z. B. be a simple check valve, which is a filling of the interior 13 the shell 12 with liquid foam concrete mass 15 allows, but a re-emergence of foam concrete mass 15 through the valve 37 locks through. The valve 37 but can alternatively z. B. also be a manually operable or switchable check valve or the like.

A feed of liquid foam concrete mass 15 in the shell 12 into it until the shell 12 is completely filled. Immediately after filling, the delivery line 38 or. 38b from the valve 37 or from the inlet 36 be separated. For this purpose, a merely indicated coupling point 45 in the manner of a coupling device in the region of the valve 37 be provided.

Then, the liquid foam concrete mass 15 Harden.

A correspondingly manufactured building part or component 10 shows in a schematic sectional view 2 :

Here you can see a hardened foam concrete mass 14 that from the shell 12 is surrounded.

As evidenced by the embodiment of 1 and 2 For the sake of simplicity, it should initially be assumed that the component to be manufactured is essentially cuboid.

3 shows a building 29 , which evidenced the representation of 3 in any case, four such components 10 includes. One recognizes a respect 3 left side wall 23b , a respect 3 right side wall 23a , and a respect 3 front side wall 23c , Finally, there is a ceiling wall 24 intended.

The four components 23a . 23b . 23c and 24 may have been made separately. According to a first variant of the invention, the four components have been manufactured separately in a manufacturing plant, and then to the site, so the site of the building 29 , transported.

According to an alternative variant of the invention, the four components have been manufactured only at the construction site, and have been positioned relative to each other after the foam mass has hardened.

According to a further embodiment of the invention, each of which is a wall 23a . 23b . 23c of the building 29 providing components 10b . 10c . 10d been successively positioned, and then successively filled with liquid foam concrete mass. The filled cases 12 of the components 10b . 10c . 10d have thereby due to a filling with liquid foam concrete mass 15 not only each taken their ultimate geometric form of space, but also taken their mounting position directly or this no longer changed.

After the curing of the wall components 10b . 10c . 10d Can then the ceiling element, so the device 10a filled and directly on the cured wall elements 23a . 23b . 23c be put on.

In the embodiment of the 3 one recognizes connecting elements or anchor elements 42a . 42b , each two components of the invention 10 connect with each other. This may be conventional fasteners such as holders, anchors or support anchors, for example with the aid of screws or dowels, firing pin or the like.

As evidenced by the embodiment of 3 the building to be finished has side walls 23a . 23b . 23c and a ceiling wall 24 on. Such geometries are the buildings to be manufactured 29 but of course not limited. The component to be manufactured can be any kind of wall 22 of a building. In particular, components of the invention can also be used to bottom wall elements 25 to train in 3 are merely indicated.

The case 12 may be made of textile material, and for example, have small openings or pores, through which the liquid foam concrete mass 15 at least to some extent can escape. However, the material needs the shell 12 be chosen and trained so that at most extremely small mass proportions of this liquid foam concrete mass 15 from the inside 40 the shell 12 through the shell 12 through to the outside 41 the shell 12 can escape through it.

On the outside 41 the shell 12 can, anyway 2 schematically shows, immediately a layer of mortar 26 and / or a plaster layer 27 and / or a color coat 28 be applied. This is right on the shell 12 or on the outside thereof 41 or alternatively also on the partly outwardly penetrated Schaumbetonmassenanteilen, after the curing of which is easily fastened. It forms on the outside 41 the shell 12 a very good primer.

As evidenced by the embodiment of 1 are included in the invention embodiments in which the device 10 only a single chamber 30 having.

Of the invention but also embodiments are included, as for example in the 4 and 7 is shown, wherein the shell 12 into several chambers 31a . 31b . 31c is divided.

In the embodiment of the 4 the peculiarity is that of a shell 12 with three chambers 31a . 31b . 31c only a single inlet 36 assigned. Here you can find on the left side of the 4 a communication channel 32 who ensures that the inlet 36 with all three chambers 31a . 31b . 31c communicated. By contrast, in the embodiment of the 7 provided that the sheath 12 into three completely separated chambers 31a . 31b . 31c is divided. Here is each of the individual chambers 31a . 31b . 31c each with its own entrance 36a . 36b . 36c assigned.

Of course, in this embodiment, each inlet must 36a . 36b . 36c also a separate valve 37a . 37b . 37c be assigned. Such structures are known, for example, from air mattresses having a plurality of valves for inflating the individual chambers of the air mattress.

Different chambers 31a . 31b . 31c a shell 12 a component according to the invention 10 can also be filled with foam concrete masses of different densities. As a result, for example, skeletal stiffening structures within a component 10 to be provided.

For this purpose, the invention also proposes a novel mixing container or a mixing device, that of the mixing device 19 from the 1 is similar, but here is not shown in the figures control device of the mixing device 19 is assigned, by means of the mixing ratio between cement paste 16 and foam 17 can be varied and / or adjusted. In this way, in particular using identical constituents, the bulk density of the foam concrete to be produced can be adjusted and / or varied only by changing the mixing ratio.

As evidenced by the embodiments of the 9 to 11 It is clear that a device according to the invention also directly a building 29 can provide altogether. The building 29 the 9 to 11 is designed essentially in the manner of a dome tent and includes - with the exception of a door opening 44 - a dome-shaped or dome-like structure. The side walls of this building 29 flow smoothly, providing curved space surfaces in the ceiling area.

For example, this building may have a height of between 1.50 meters and 3 meters.

According to one embodiment of the invention, the shell 12 this building element of 9 to 11 formed continuously and in one piece.

The case 12 may for example have a plurality of chambers. 11 in this context again indicates three chambers, each of the chambers having its own entrance 36a . 36b . 36c assigned.

When filling the case 12 with liquid foam concrete mass 15 spreads the foam concrete 15 under pressure in the designated chamber.

As a result of the pressure, a spatial shape of the component is achieved, the ultimately desired shape of the component 10 already corresponds. The shell is thus chosen or provided so that automatically when filling the envelope with liquid foam concrete mass this geometric shape is achieved.

building 29 , as in the example 9 to 11 could, for example, serve as emergency shelters and be used for example in disasters, especially natural disasters. In the event that must be provided at short notice housing, appropriate equipment, such. B. of aid organizations, shipped quickly or transported.

For example, in a conventional standard overseas container, a variety of prepared formwork or shells 12 are housed, which in principle take up no more space than tents. Furthermore, technical equipment may be arranged in such a container for mixing and manufacturing cement paste and foam and for mixing the two components.

On site, in principle, only cement has to be found. In a short time, a variety of such residential accommodation can be provided, the people in distress is quickly offered a solid roof over his head, which is much more stable and weather resistant, than conventional tents or emergency shelters using corrugated iron, foil or wood or the like Materials.

As evidenced by the embodiment of 13 can inside the interior 13 the shell 12 transverse fibers 34a . 34b . 34c be provided. For example, these may be individual strands or area sections. These can be used, for example, to absorb additional lateral forces if, for example, further earthquakes are to be expected in seismic areas, and serve a better resistance of the building constructed with the aid of the components according to the invention against transverse forces and transverse vibrations.

Claims (13)

Building element (10) for a building (29), in particular in the manner of a prefabricated concrete part, comprising a sheath (12) of a flexible, e.g. textile, material providing a completely closed and / or closeable interior (13) filled with a foam concrete mass (15). Component after Claim 1 , characterized in that the foam concrete mass consists of a mixture (18) of a cement paste (16) with a foam (17). Component after Claim 1 or 2 , characterized in that the cured foam concrete mass (14) has a density of less than 300 kg / m ³ . Component according to one of the preceding claims, characterized in that the component (10) has a wall (22), such as side wall (23a, 23b, 23c), ceiling wall (24) or bottom wall (25), or a part of a wall of a building, provides. Component according to one of the preceding claims, characterized in that the sheath (12) on its outer side (41) at least partially with a mortar layer (26) and / or a plaster layer (27) and / or a color layer (28) can be acted upon or acted upon is. Component according to one of the preceding claims, characterized in that the component (10) forms at least one side wall portion and at least one ceiling wall portion of a building. Component according to one of the preceding claims, characterized in that the component (10) directly a building ( 9-11 ) trains. Formwork (11) for a foam concrete mass, comprising a flexible, tubular and / or bag-like shell (12), which provides a fully closable interior (13). Formwork after Claim 8 , characterized in that the sheath (12) comprises a plurality of chambers (31a, 31b, 31c). Formwork after Claim 9 , characterized in that the chambers communicate at least partially with each other ( 4 ). Formwork after Claim 8 , characterized in that the chambers are separated from each other ( 7 ). Formwork according to one of the Claims 8 to 11 , characterized in that the shell (12) has at least one inlet (36, 36a, 36b, 36c) for a foam concrete mass. Method for producing a building element (10) for a building (29), comprising the following steps: a) providing a cement glue (16), b) providing a foam (17), c) mixing cement paste and foam into a foam concrete mass (15), in particular in a mixing device (19), d) feeding the foam concrete mass (15), in particular with the aid of a pump (39), to an inlet (36) of a flexible casing (12), and completely filling the casing, e) closing the inlet, z. By closing a valve (37a, 37b, 37c), f) allowing the foam concrete mass to harden.

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