DE3132340A1 - Process for producing wall elements, and wall element which is produced by the process and is intended for the construction of prefabricated buildings - Google Patents

Abstract

Process for the simplified and less expensive production of wall elements which are improved in terms of their precision and quality, are intended for the construction of prefabricated buildings and are formed by the sandwich construction method from two panels, produced from wood cement, and webs, connecting the panels and adhesively bonded to the panels, as well as, if appropriate, filler in the spaces enclosed by the panels and webs. For this purpose, the use of unfinished wood-cement panels as starting material is provided. It is furthermore provided that, by trimming the unfinished panels to the width of the elements by sawing or milling, the unfinished panels are continuously copy-milled on one side, in the region of the border and intermediate webs to be bonded in, and starting from one unfinished side, to a predetermined thickness which is kept within narrow tolerances. After this, once adhesive has been applied on those surfaces of the panels to be adhesively bonded, webs of two panels, with their milled reliefs facing one another, are adhesively bonded to the webs inserted therebetween by exerting a transversely applied pressure. The wood-cement panels of the wall elements accordingly have milled reliefs, which reduce the wall elements to a uniform thickness dimension, in the region of the webs. <IMAGE>

Description

Process for the production of wall elements and according to the process manufactured wall element for the construction of prefabricated buildings.

For the production of wall elements for the construction of prefabricated buildings, such as residential buildings, warehouses and workshops, wood-cement panels have become a material or the starting material is particularly well-proven, as wood cement is water- and weatherproof, and fire-proof and is resistant to termites, fungi and rot, as well as to the common ones Wall coverings can be provided. As wood cement panels are here made of highly compressed Cement-bonded wood chips with a density of 1250 to 1400 kp / m3 - to be understood. It is known that these wood cement panels in sandwich or to process in folding construction. In the sandwich construction, two wood cement panels are used connected to one another by bars made of square timber or metal profiles, whereby Square timbers have proven to be unsuitable because wood is not very durable and also works while metal profiles are made Disadvantageous for reasons of cost are. In the folding construction, the wood cement panels are spaced accordingly the outer dimension of the element notched, folded and glued together so that the result is a panel with double-angled edges, which on its own is not a fully-fledged one Wall element results. Now wood cement panels can only be made with thickness tolerances of + 1 mm. Without double-sided, symmetrical and full-surface post-processing of the panels, the wall elements made from them have considerable differences in thickness on and the joining of the wall elements on abutment is without significant impairment the appearance not possible and cover strips over the joints or shadow grooves along the parting line do not provide a satisfactory solution. Hence the wood cement panels mostly reworked, and around the thin fine layer on both surfaces The post-processing takes place in order not to remove or damage the plates too much by sanding both sides of the plate over the. full areas. High investment costs for the required precision machines, high energy consumption and consumption Grinding tools make reworking expensive, and the resulting grinding dust brings with it further problems.

The invention is based on the object of improved wall elements Easier and cheaper to manufacture in high precision and quality. To solve this According to the invention, the object is the use of wood-cement raw panels as insert material and further provided that with the trimming of the tube plates to the width of the Elements by sawing or milling continuously the raw panels in the area of the glued Edge and intermediate webs starting from a raw side on one side on a predetermined, within tight tolerances maintained thickness are copy-milled, whereupon after the adhesive has been applied to the surfaces of the plates and webs to be glued, two with their cutouts facing each other with the interposed webs be glued when exerting a transversely applied pressure.

Up until now, it was always the case that the wood cement panels were always symmetrical in one to process the fine layer over the full area with the dimensions preserved on both sides, are carried out in accordance with of the invention used wood cement raw panels that require processing only on one Side experience, with the fine layer on this side in the area of processing can possibly be completely removed. With raw panels are within the meaning of the present Invention to understand wood cement panels, the main surfaces of which after pressing the No post-processing, especially no large or full-area panels Have undergone post-processing to reduce dimensional deviations in their thickness, without edge processing, trimming or cutting being excluded. With the decision in favor of the sandwich construction, which is also part of the inventive solution of the wall elements, this is possible without any disadvantage, since they are part of the manufacturing process weakening of the wood cement panels with the completion of the wall element for this is of no significance or disadvantage. Those made of wood cement panels and connecting them have wall elements formed with them bonded webs in sandwich construction according to the invention, due to the production, surfaces of the wood cement panels that are turned outwards in the raw state, while the wood cement panels in the area of the webs on the after internally swept surfaces have cutouts that are on the wood cement panels and This means that the wall elements have a uniform thickness dimension within the required range Tolerances result for a Joining the wall elements together Shock are a prerequisite.

Depending on the intended use of the wall elements, these are except for the Edge and intermediate webs running in the longitudinal direction also with in the transverse direction extending webs (edge webs and, if necessary, intermediate webs). According to a further feature of the invention, the raw panels are then used for this purpose subjected to the longitudinal trimming to the width dimension of a transverse trimming to the length dimension, the same as with longitudinal trimming in the area of the transverse edge and transverse intermediate webs to be glued the raw panel are copy-milled to the predetermined thickness, whereupon the Panels and the longitudinal edge, transverse edge, longitudinal intermediate and transverse intermediate webs Adhesive application are glued while exerting a transverse pressure.

The exertion of the transverse pressing pressure can be carried out in conventional press rolling mills or pressing, with several wall elements of the same dimensions in the stack lying on top of one another can be exposed to the pressing pressure together. Thickness fluctuations of the raw panels, which form local convexities between the areas of the webs can lead to the surfaces of the wall elements, then lead to bending stresses in the plates in the area between the webs. Such bending stresses are avoided if, according to a further feature of the invention, the transverse compression pressure only exercised locally in the immediate area of the longitudinal and, if applicable, transverse webs what is adapted by grate-like or grid-like the position of the webs in the wall element Press plates as a support, pad or as an intermediate layer at the same time Pressing several wall elements in a stack can be achieved. When using of press rolling mills for exercise of the transverse pressing pressure, the offers the advantage of a continuous flow of material, it is possible to use the roll bales to hold in the area between the webs with a slightly smaller diameter so as to to limit the pressure to the areas of the webs.

The wall elements have particularly high insulation values and / or strength required is a filling of the chambers remaining between the plates and webs necessary. Cuttings of mats, fleece or panels may be used as filling also fittings of conventional insulation materials against heat and / or sound transmission in question. For example, blanks of quilted glass wool webs can be inserted into the Chambers be inserted. Furthermore, for example, blanks of lightweight panels, these are low-density boards made of cement-bonded wood wool with one density from 400 to 450 kp / m3, which are inserted into the chambers with expansion adhesives and completely fill the chambers with the expanded adhesive, with an excess at adhesive in the pores of the panels can escape.

Filling the chambers with polyurethane foam has proven to be particularly advantageous highlighted, since polyurethane foam is a good connection with very high insulation values of the panels and is also characterized by its particularly low weight (density of 40 kp / m3).

So far a sufficiently strong connection due to the filling of the chambers of the panels is produced, for example with blanks of lightweight panels, which are glued on all sides in the chambers, especially with polyurethane foam is possible can on the use of Intermediate bars depending on Size of the wall element can be largely or completely dispensed with.

The fillings are introduced according to a further feature of the invention when joining the plates and webs in the thereby forming Chambers. During the subsequent pressing for gluing, the pressing pressure is increased. expedient Maintain this until the reaction (foaming or expansion of the adhesive) is finished, that is, up to about 6 min.

In order to ensure the dimensional stability of the wall elements are in accordance with Another feature of the invention is the webs connecting the wood cement panels also made of wood cement.

In those used as abutment surfaces when assembling the wall elements According to a further feature of the invention, edge surfaces are grooves for introduction provided by springs to connect the wall elements.

Further details and features of the invention are based on exemplary embodiments described, which are shown in the drawings. They show: FIG. 1 a part a prefabricated house made of wall elements according to the invention in an exploded view.

FIG. 2 shows a cross section of a wall element and in FIG. 3 a cross section of another wall element to which the figure 4 and FIG. 5 show details on a larger scale. FIG. 6 shows in Side view only part of the plant for the production of the wall elements according to the invention The method of which a detail is shown in FIG. 7 in a perspective illustration is. Another part of the manufacturing plant is shown in FIG. 8, likewise in perspective Depiction.

Fig. 1 shows the principle of assembling a building using of the wall elements according to the invention. With 1 the foundation is referred to, which carries a frame, not shown here, on which the wall elements 2 in the various required sizes 2a and 2b are attached. The wall elements 2a are supplemented and 2b by further elements such as door elements (in the detail shown in FIG. 1 not shown), window elements 3 and additional elements 2c. The connection the wall elements 2a, 2b and 2c with each other is carried out by springs 4, which are in grooves 5 seated, with which the wall elements 2a, 2b and 2c to the pending for connection Butt surfaces 6 are provided, as Figure 4 illustrates on a larger scale.

Where wall elements meet at an angle, corner posts 7 are provided, the same as the wall elements 2 at their abutment surfaces 6 at their one Wall element 2 facing sides are provided with grooves for receiving springs 4.

The window elements 3 overlap with the cheeks 8 of their outward U-shaped open edge the wall elements 2, the horizontally adjacent Wall elements 2a in the area the connection of a window element 3 can be provided with prefabricated filler pieces 9 At the upper edge are the wall elements 2a and 2c connected with bandages 10 and thereby held together and stiffened transversely.

Individual wall elements and their connection with the same wall element Figures 2 and 3e show the connection point as a detail on a larger scale is shown in Fig.4 The wall element shown in Fig. 2 consists of two wood cement panels 11aç, at least on their long sides, if necessary are also connected to one another on their transverse sides by edge webs 12. For the Use shown in Fig. 1, the wall elements 2a and 2b require edge webs 12 on the long sides and only on one transverse side, while the wall element 2c only Edge webs 12 required on the long sides. The edge webs 12 are like the plates 11a Made from wood cement to ensure dimensional and dimensional stability, but also other resistance of wood cement to use. The edge webs 12 are three-sided machined to the flatness of the abutting surfaces 6 and the thickness of the wall elements 2 in the To be able to grant impact area within narrow limits. For the latter reason are also the wood cement panels 11a starting in the areas to be connected with edge webs 12 from the raw outer surfaces 13 through one-sided cutouts 14 to a narrow tolerance Thickness dimension machined The cavity between the wood cement panels 11a is with a Polyurethane foam layer 15 foamed.

The polyurethane foam layer 15 connects to the wood cement panels 11aa whereby this composite results in a wall element of very high stability and strength and it can be entirely on intermediate webs in these wall elements be waived. This is at least the preferred embodiment of the wall elements for exterior walls and other walls subject to high mechanical loads 0 The one shown in Fig. 3 lffiRndelement is a hollow frame construction in which the wood cement panels 11b all around by longitudinal and transverse edge webs 12 and by intermediate webs 16, which at least can be set lengthways and, if necessary, also crosswise. The editing the longitudinal edge and transverse edge webs 12 and the wood cement panels 11b in the area of Edge webs 12 is the same as described for FIG. 2. The same as the edge walkways 12 are also the intermediate webs 16 in their distance of the wood cement panels 11b the determining dimensioning machined with close tolerance, and there are also the wood-cement panels 11b in the area of the intermediate webs 16 by millings 17 starting from the raw Outer surfaces 18 machined to a tightly tolerated thickness dimension, as shown in FIG. 5 can be seen in more detail. The voids between the wood cement panels 11b, the Edge webs 12 and the intermediate webs 16 are stitched with blanks 19 of Glass wool sheets filled, with these to secure their position on one of the wood cement panels 11b can be pinned.

As can be clearly seen in FIGS. 4 and 5 in particular, are through the one-sided cutouts 14 and 17, the wood cement panels 11 and the connection the wood cement panels 11 through the wood cement webs 12 and optionally 16 with simple means and with very little processing effort high quality wall elements emerged that were just as easy and cheap, with no joints or coverings or acceptance from noticeable dislocation jumps, but also joined together with a good seal can be, the quality of the connection provided here by means of grooves and Spring is given by the fact that the grooves 5 and existing in the wood cement thus very shape and dimensionally stable edge webs 12 simple, but with high precision can be manufactured.

Wall elements according to the invention, as described above, are used special process for their manufacture precedes, of which an essential operation as part of the production of the wood cement panels 11b for one shown in FIGS. 3 to 5 illustrated wall element is described with reference to FIGS. 6 and 7, wood chips, which A cement-based binder is added in layers that are as even as possible (Fine layers as top layers above and below and a coarser layer in between) applied to plates and pressed into plates in multi-stage presses under high pressure. The type of manufacture requires that the thickness of the plates over the entire surface fluctuates between 1 mm above and 1 mm below the nominal dimension. The panels are then stacked in an interim storage facility, where they continue to dry and harden immediately Before further processing, the panels are passed through a dryer again, so that the panels are evenly dry for processing Wood cement board 20 thus produced and prepared in a known manner is on a roller table 21 aligned and driving roller sets 23 and 24 fed to the Move the panel 20 by means of hemming saws 25, two of which are spaced apart from the panel width Set saw blades 27 cut off the seam strips 28 and the plate 20 on trim the prescribed width even before the Plate 20 from the drive roller set 23 runs out, its leading end is from the drive roller set 29 and later also detected by the drive roller set 30, so that a constant leadership of the Plate 20 is guaranteed. The drivers 23, 24, 29 and 30 have rollers with limited resilient jackets to compensate for unevenness, and the top roller are to compensate of fluctuations in the thickness of the plates 20 resiliently against the fixedly mounted Pressed lower rollers. The saws 25 are arranged downstream in a roller table 21 spanning Bridge 31 in the vertical direction against the plate 20 adjustable milling heads 32 and 33, of which the milling heads 32, which are arranged on the plate edges, are the milled areas 14 in the area of the edge webs 12 and the milling heads 33, the cutouts 17 in the area the intermediate webs 16 of the wood cement board 11b to be produced for a wall element according to FIGS. 3 to 5 generate. The cutter shafts in the cutter heads 32 and 33 are connected to each other and to the drive by articulated spindles 38. Every milling head 32 and 33 can be employed by themselves, the employment via not shown Employment and control means takes place. The control means are designed as copier units, and each milling head 32 or 33 is assigned a feeler roller 34, which consists of a stationary encoder housing 35 pressed resiliently against the underside of the plate 20 is. The movement of the roller tappet 36 follows via the encoder in the housing 35, the line connection 37 and the copier the employment of the milling heads 32 and 33 such that the depth the cutouts 14 and 17 always the same distance to the opposite, from one The sensing roller 34 scanned the surface portion of the plate 20 and thus the plate 20 In the area of the milled recesses 14 and 17, the same thickness everywhere within permissible tolerance limits having.

As in the production of wood cement panels 11a, only milled-out portions are used 16j is required for edge webs 12, a bridge spanning the roller table 21 is omitted 31. The milling heads 32 can be in C-shaped stands encompassing the plate edges be movably supported by a copier. Is the C-shaped stand opposite the milling head with a support roller and, in addition, with the edge of the plate If the support roller is provided that presses the hold-down roller, the copier can also do this omitted so that a considerable simplification of the machine effort results.

After the panels have been processed lengthways, a Transverse processing in which the panels are cut to the desired length and at the same time the cutouts for the necessary transverse edge and transverse intermediate webs getting produced. The panels are then sent to an intermediate storage facility In the manufacture of the wall elements, identical panels are then brought together in pairs with the necessary edge and dividing bars. Next is the application of the Glue in the area of the cutouts and on the two opposite sides The bars When the plates and bars are assembled, they are also introduced of the fillings as a cut or as the required amount of a reaction mixture. The assembled panels are then placed in a press in stacks and subject to transverse pressure until the bonded joints are firm and possibly Reaction mixtures introduced as fillings are foamed or introduced with fillings Expansion adhesive have solidified.

Instead of a press, a rolling mill can also be used to produce the transversal Pressing pressure to bond the plates and webs are used1 as this is the case Fig. 8 shows schematically. The rollers 40 are according to the spacing and number of the webs 41 between the plates 42 provided with annular zones 43, which over the rest The ball area of the rollers 40 protrude so that the rollers 40 only have these ring zones 43 act on the wall elements. The plates 42 are thus not subjected to any bending stress when pressing, not even if there are slight unevenness of the plates 42 in the areas between the webs 41 should be present.

The rollers 40 are expediently provided with a hard rubber jacket, in order to achieve an even distribution of pressure on all zones. Of course several sets of rollers can be arranged one behind the other in order to reduce the pressing pressure to be able to exercise for a long time.

Claims (7)

Patent claims 1. Process for the production of wall (exterior wall, Interior wall, ceiling and roof elements for the construction of prefabricated buildings that in sandwich construction from two panels made of wood cement and the panels connecting webs glued to the plates and optionally filler in the spaces enclosed by the plates and webs are marked through the use of raw panels as insert material and the fact that with the Trimming the raw panels to the width of the elements by sawing (27) or milling continuously the raw panels in the area of the edge and intermediate webs to be glued (12, 16) starting from a raw side (13, 18) on one side to a predetermined, be copy-milled within tight tolerances, whereupon the adhesive is applied on the surfaces to be glued of the plates (11) and webs (12, 16) two with their Milled recesses (14, 17) facing plates (11) with the interposed Bars (12, 16) bonded when a transversely applied pressure is exerted will. 2. The method according to claim 1, characterized in that subsequently to the lengthwise trimming to the width dimension a transverse trimming to the length dimension and thus the same as with longitudinal trimming in the area of the transverse edge- and transverse intermediate webs, the raw panels are copy-milled to the predetermined thickness and then the panels and the longitudinal edge, cross edge, longitudinal intermediate and transverse intermediate webs be glued after applying the adhesive while exerting a transverse pressure. 3. The method according to claim 1 or 2, characterized in that the transverse pressure only locally (43) in the immediate area of the longitudinal webs (41) and optionally the transverse webs is applied. 4. The method according to any one of claims 1 to 3, characterized in that that when the plates (11) and webs (12, 16) are joined together, fillings (15, 19) (reaction mixture a foam or molded body or cuts made of insulating material with or without expansion adhesive) be introduced into the chambers between the plates (11) and webs (12, 16). 5. Wall element in sandwich construction for the construction of prefabricated buildings, consisting of two wood cement panels and connecting the panels, glued to them Web and optionally filler in those enclosed by the plates and webs Broaching, characterized in that the wood-cement panels (11) in the area of the webs (12, 16) have cutouts (14, 17) which the wood cement panels (11) on a uniform thickness based on the outward facing surface (13, 18) of the Decrease wood cement panels (11). 6. Wall element according to claim 5, characterized in that the web (12, 16) consist of wood cement. 7 wall element according to claim 5 or 6, characterized in that the Butt surfaces (6) with grooves (5) milled into the webs (12) for insertion of the elements connecting springs (4) are provided 8 wall elements after a of the preceding claims, characterized in "that it is foamed with polyurethane (15) is provided