DE20009272U1 - Building component with insulation mat - Google Patents

Description

LEMCKE · BROMMER S. PARTNER

PATENT ATTORNEYS

BISMARCKSTR. 16 ■ D-76133 KARLSRUHE

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23 May 2000 18 152 (B/gr)

Schock Components GmbH Vimbucher Strasse 2 76534 Baden-Baden

Building component with insulation mat

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LEMCKE-BROMMERSlPARTNER "*' * **' ^1M * "··**··*

PATENT ATTORNEYS

BISMABCKSTB. 16 ■ D-761 33 KARLSBUHE

23 May 2000 18 152(B/gr)

Description

The invention relates to a building part made of hardenable building material, in particular concrete, on which an insulating mat made of foamed plastic is arranged on at least one side surface for acoustic and/or thermal decoupling from an adjacent part. The invention also relates to an insulating mat for such a building component.

The main application of the invention is impact sound insulation on stairs between the flight of stairs or stair landing on the one hand and the treads or the adjacent staircase wall on the other hand, which is why the following description is based on this application without the invention being limited to it.

Increasing attention is being paid to sound insulation in the stair area. For example, Pörschmann's "Impact sound insulation for concrete stone stairs", tg treppe + geländer 2/1987, introduced the idea of gluing an insulation layer onto a conventionally concreted staircase and then applying the mortar bed for the angle steps to this insulation layer, so that the treads and their substructure are acoustically decoupled from each other.

Flexible foam mats are particularly suitable as insulation material. However, such foam mats do not form a stable bond with the underlying mortar layer, which serves as a connecting material and in which the stepping stones are usually laid.

The applicant has therefore already proposed in DE 298 15 588 to coat the underside of the insulation mat with granular material, in particular sand. In this way, the surface of the insulation mat, which consists of a relatively smooth foam skin, is roughened and forms an intimate bond with

the mortar bed or the adjacent part of the building. However, the sand layer must be glued to the insulation mat, which makes production more expensive. Furthermore, the applicant has proposed in GM 299 09 421 that the insulation mat be open-pored at least locally on its bottom and/or top. These open pores offer the pasty connecting material - i.e. the mortar layer - the opportunity to penetrate into its cavities and harden there, which leads to a particularly good bond between the two materials.

The present invention is based on the object of expanding the application of the proposed open-pore insulation mat, in particular when a connecting layer, such as mortar, between the building component and the insulation mat can be dispensed with. The invention should also be characterized by advantages in the manufacture of the building component.

This object is achieved according to the invention in that the insulation mat is at least locally open-pored on its side adjacent to the building component and in that it is connected to the building component in that the uncured building material of the building component or a mortar bed applied thereto has penetrated into the open pores of the insulation mat.

According to the invention, the insulation mat is therefore bonded to the building component directly or via the mortar bed and with sufficient strength.

This makes it possible to connect the insulation mat to the precast part during production in the factory by attaching it to the inside of the precast formwork and then pouring concrete into the formwork so that the liquid concrete can penetrate into the open pores of the insulation mat. After the formwork has been removed, the insulation mat is then positively connected to the precast part. The same advantages naturally also apply when producing components from in-situ concrete on the construction site.

The building component often forms several abutting and/or overlapping surfaces with neighboring building parts. In order to achieve optimal decoupling of the building component from the neighboring parts, it is therefore advisable to arrange insulation mats on all side surfaces of the building component that are adjacent to neighboring parts.

Stair landings, flights of stairs, treads or staircase walls are particularly suitable building components. In order to acoustically decouple a staircase landing from the surrounding staircase walls, the insulation mats can either be connected to the staircase landing or to the corresponding staircase walls. The same applies to decoupling a flight of stairs from the staircase walls.

However, it can happen, particularly with stair landings, that the side surfaces of the stair landing adjacent to the surrounding stairwell walls are optimally decoupled from them by the insulation mats, but that sound bridges still occur on the top or bottom of the stairwell walls, especially if a floor covering made of tiles or similar applied to the stair landing hits the stairwell wall and thus forms sound bridges. To prevent this, it is therefore advantageous if the insulation mat has an edge that protrudes above the building component, in particular upwards, which shields the floor covering from the adjacent wall.

As far as the nature of the insulation mat itself is concerned, it is difficult to produce insulation mats made of foamed plastic with an open-pored top or bottom, especially if they are to be sold by the meter at low cost. Instead, due to the manufacturing process, they have a continuous foam skin on the surface, which means that all the pores are closed.

This foam skin could be removed either mechanically or chemically using solvents, at least locally, thereby exposing the pores. However, both methods make production more expensive, and the chemical solvents cause additional environmental problems. A particularly useful development of the invention therefore consists in dividing the insulation material lengthwise into two or more strips using a dividing process, with the dividing plane running parallel to the foam skin. The dividing process, which corresponds to splitting the material, cuts open trapped air pores and gives the desired open-pored surface. If there is still a foam skin on one side of the strip, this is not critical, since only the side to be connected to the building component needs to be open-pored. The insulation mat is usually attached to the formwork with one side during concreting, which is usually done using double-sided adhesive tape, so it is actually advantageous to leave the foam skin on this side.

Further features and advantages of the invention will become apparent from the following description of embodiments with reference to the drawings, in which

Figure 1 shows an oblique view of a spiral carpet section with an open-pored insulation mat arranged on the side; Figure 2 shows an enlarged cross-section through the one-sided open-pored insulation mat;

Figure 3 is a plan view of a single-flight straight staircase with insulation mat arranged on the side;

Figure 4 is a plan view of a stair landing with insulation mats arranged on the sides.

Figure 1 shows a spiral staircase construction 1 and a staircase wall 2 surrounding it at right angles. The staircase construction 1 consists of a stepped substructure 4 on which the usual treads 5 and risers 6 are laid. The treads 5 run horizontally on the steps of the substructure, while the risers 6 are perpendicular to the treads 5 and extend from the rear end of a lower tread to approximately the front end of an upper tread.

The insulating mat 3 according to the invention is arranged between the substructure 4 on the one hand and the tread plates 5 on the other hand.

There are two ways of installing the insulation mat 3. Either it is connected to the concrete substructure 4 during production by attaching it to the inside of the formwork before pouring the fresh concrete so that the open-pored side faces the inside of the formwork. The fresh concrete then penetrates into the open pores during pouring and thereby forms a positive fit with the insulation mat. The staircase structure 1, which is designed as a prefabricated part, is then connected to the insulation mat

3 installed in the manner shown.

Or the insulation mat is applied later to the substructure that has already hardened and is installed in the stairwell. In this case, it is connected by a mortar bed that is applied to the substructure, onto which the insulation mat is placed with its open-pored side.

In both cases, the tread plates 5 are supported by the

4 connected insulation mat 3 circuit-insulated.

The tread plates are connected to the insulation mat by gluing.

To prevent sound bridges from forming from the treads to the staircase wall and/or to the risers 6, the insulation mat protrudes slightly over the individual horizontal surfaces of the steps of the substructure 4 with an overhang 3a. Only after the treads 5 have been placed on the insulation mats 3 is the overhang 3a trimmed along the contours of the stairs 1, whereby any remaining overhang can be useful by folding it down onto the tread in order to decouple the risers and possibly also the base tiles on the staircase wall from the tread.

The overhang 3a can be an integrally formed part of the insulation mat 3. However, it can also be separate insulation strips.

Figure 2 now shows the one-sided open-pored insulation layer 3, which is arranged between the staircase 1 and the staircase wall 2.

The insulation mat 3 consists of foamed plastic, in particular PE or PU foam, and has the usual foam skin 3' on its upper side.

On the underside, however, the insulation layer is open-pored. This open-poredness was achieved by splitting a double-thickness insulation layer into two layers in the middle. The open-poredness ensures a particularly stable connection to the concrete or mortar bed of the substructure 4, which is resistant to horizontal forces.

On their upper side, the insulation mats are glued to the tread plates 5 via their foam skin 3'.

The insulation mat is shown here greatly enlarged; its actual thickness is about 3 mm to 8 mm, preferably 5 mm. The pore size of the foam is at least 0.5 mm, preferably about 1 mm.

Figure 3 now shows a single-flight straight staircase 8 with steps 9. Clearly visible is a one-piece continuous insulation mat 10, which is arranged between the staircase 8 and the adjacent wall 11. Here, the insulation is not between the substructure and tread plates, but between the substructure with tread and riser plates on the one hand and the adjacent staircase walls on the other.

As in the embodiment in Figure 1, the side of the insulation mat 10 facing the stairs is also open-pored, so that it was positively connected to the substructure of the stairs 8 during manufacture and acoustically insulates the adjacent staircase wall 11. On the side facing the wall 11, the insulation mat 10 has the usual foam skin 10'.

Finally, Figure 4 shows a substantially rectangular stair landing 12, which is surrounded by three side surfaces by staircase walls 13. Between these side surfaces of the stair landing and the staircase walls are
Insulation mats 16 are arranged, the insulation mats being connected to the stair landing in accordance with the invention. The insulation mats 16 have a vertically upwardly projecting edge, through which any covering to be laid on the stair landing, such as screed or tiles, can be acoustically
is decoupled from the stairwell walls.

Furthermore, Figure 4 shows support surfaces 17 of the landing 12, on which opposing flights of stairs (not shown) can rest.

In summary, the invention is characterized in that the at least locally open-pored insulation mat provides a particularly stable connection between the insulation mat and a building component in a cost-effective manner.

Claims (10)

1. Building component ( 4 , 8 , 12 ) made of hardenable building material, in particular concrete, on which an insulating mat ( 3 , 7 , 10 , 16 ) made of foamed plastic is arranged at least on one side surface for acoustic and/or thermal decoupling from a neighboring part ( 2 , 5 , 11 , 13 ), characterized in that the insulating mat ( 3 , 10 , 16 ) is at least locally open-pored on its side adjacent to the building component ( 4 , 8 , 12 ) and that it is connected to the building component ( 4 , 8 , 12 ) by the unhardened building material of the building component ( 4 , 8 , 12 ) or a mortar bed applied thereto being inserted into the open pores of the insulating mat ( 3 , 10 , 16 ). has penetrated. 2. Building component ( 4 , 8 , 12 ) according to claim 1, characterized in that insulating mats ( 3 , 10, 16 ) are arranged on all side surfaces of the building component ( 4 , 8 , 12 ) which form abutting or overlapping surfaces with the adjacent parts ( 2 , 5 , 11 , 13 ). 3. Building component ( 4 , 8 , 12 ) according to claim 1, characterized in that the building component ( 4 , 8 , 12 ) is a stair landing ( 12 ), a flight of stairs ( 4 , 8 ) or a stairwell wall ( 2 , 11 , 13 ). 4. Building component ( 4 , 8 , 12 ) according to claim 1, characterized in that the insulating mat ( 3 , 10 , 16 ) has an edge ( 3a ) which projects in particular upwards relative to the building component ( 4 , 8 , 12 ). 5. Insulating mat ( 3 , 10 , 16 ) for a building component ( 4 , 8 , 12 ) according to one of claims 1 to 4, characterized in that the insulating mat ( 3 , 10 , 16 ) is made from meterware with a foam skin ( 3 ', 10 ', 16 ') on its upper and/or lower side and this foam skin ( 3 ', 10 ', 16 ') is at least locally removed. 6. Insulating mat ( 3 , 10 , 16 ) according to claim 5, characterized in that the foam skin ( 3 ', 10 ', 16 ') is completely removed. 7. Insulating mat ( 3 , 10 , 16 ) according to claim 5, characterized in that the foam skin ( 3 ', 10 ', 16 ') is removed only on the underside of the insulating mat. 8. Insulating mat ( 3 , 10 , 16 ) according to claim 5, characterized in that it consists of a web split or peeled off from the starting material. 9. Insulating mat ( 3 , 10 , 16 ) according to claim 8, characterized in that the starting material ( 2 ) is divided into strips of approximately equal thickness. 10. Insulating mat ( 3 , 10 , 16 ) according to claim 8 or 9, characterized in that the dividing plane runs parallel to the foam skin ( 3 ', 10 ', 16 ').