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US20070051061A1 - Wall element - Google Patents

Wall element Download PDF

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Publication number
US20070051061A1
US20070051061A1 US10/549,073 US54907304A US2007051061A1 US 20070051061 A1 US20070051061 A1 US 20070051061A1 US 54907304 A US54907304 A US 54907304A US 2007051061 A1 US2007051061 A1 US 2007051061A1
Authority
US
United States
Prior art keywords
base sheet
wall element
sheet
insulation
insulation sheet
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.)
Abandoned
Application number
US10/549,073
Other languages
English (en)
Inventor
Karl Weinmann
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of US20070051061A1 publication Critical patent/US20070051061A1/en
Abandoned 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not

Definitions

  • wood concrete that is, a material that contains wood chips and cement
  • this material is not suited for bearing static loads
  • recesses are made in the molded blocks that are either filled with concrete or serve to receive elements in a supporting structure, for instance made of wood or steel.
  • the material has the advantage that it is open to diffusion and ecologically unobjectionable.
  • wood concrete has a thermal conductivity that is approximately comparable to that of solid wood. This means that the wall elements must have a thickness of approximately 36 to 40 cm so that the wall will have a thermal insulation value that meets the passive home standard. Building walls that are put together from such thick wall elements, however, can hardly be transported, because of their weight.
  • a wall element particularly for manufacturing the outer walls of buildings, which is made from a composite of a base sheet, which is made from comminuted plant material and mineral substances, and an insulation sheet of a thermal insulation material open to diffusion. Insulation sheets have an extremely low thermal conductivity. By combining this material with the base sheet, which may for instance be of wood concrete, it is possible to reduce the total thickness of the wall element markedly, compared to a wall element that comprises solely the material of the base sheet. Moreover, an insulation sheet has a lesser weight than a wood concrete slab of the same thickness.
  • the material of the base sheet can, besides wood, also be any other plant material suitable for the purpose, such as hemp, bamboo, sisal, or the like. As a binder, besides cement, magnesite can be used.
  • the insulation sheet is preferably made from wood fibers but can also comprise other plant fibers.
  • the base sheet care should preferably be taken to assure that it has a lesser or at most the same thermal conductivity as solid wood, since otherwise, given the desired relatively slight thicknesses of the wall elements, the requisite thermal insulation value is not attained.
  • a further possibility for improving the thermal insulation value of the wall element is to incorporate air chambers at least into the base sheet.
  • the volume and location of the air chambers must be selected such that convection flows of the air in the chambers cannot occur.
  • the air chambers can therefore be oriented preferably horizontally or essentially horizontally. With this location, the volume of the air chambers can be made relatively large, since convection flows of the air can develop only in the vertical direction.
  • the base sheet and the insulation sheet can be joined together by anchoring elements.
  • the ratio between the thicknesses of the base sheet and the insulation sheet can be varied.
  • the insulation sheet may be approximately 10 cm thick and the base sheet is approximately 10 to 20 cm thick.
  • the wall elements of the invention can be furnished as semifinished products to carpentry shops or to the prefabricated home-building industry.
  • recesses can be made in the base sheet for receiving elements of a supporting structure, in particular wooden posts. These recesses may be made in the surface of the base sheet, so that the elements of the supporting structure are surrounded on three sides by the material of the base sheet. However, it is also possible to indent the recesses so deeply that they extend from the surface of the base sheet as far as the insulation sheet. The elements of the supporting structure can then be joined directly to the insulation sheet.
  • the recesses can preferably be made by milling. Besides the recesses for elements of a supporting structure, installation ducts can also be made in the base sheet and/or in the insulation sheet.
  • finished outer walls of a building can be made by putting the wall elements together.
  • the insulation sheets of the wall elements form the outsides of the outer walls, since they have a lesser thermal conductivity, and they may already be provided with a plaster system or with shuttering for holding plates for covering the facade.
  • the elements of the supporting structure are placed in the recesses and secured.
  • the back side of the base sheet can be provided with a plaster system as well. The thus prefabricated walls of the building are then transported to the construction site, where they are joined to the prepared foundation and to one another.
  • the invention proposes a first method, in which the material of the base sheet is poured in the liquid state onto the back side of the insulation sheets and compacted.
  • the material of the base sheet is poured into a mold and compacted; next, the insulation sheet, moistened on the contact side with the base sheet, is placed onto the material of the base sheet and optionally pressed down.
  • Air chambers may be made in the material of the base sheet, by means of positive-displacement bodies that are located or can be located in the mold and/or by means of mixing in clumps of ice beneath the material of the base sheet. Mixing in blocks of ice can also be employed in the first method. The ice melts from the heat produced in the setting process, and the resultant water is absorbed in the setting process. If frozen positive-displacement bodies are used for making the air chambers, the wall element can easily be unmolded after the conclusion of the setting process.
  • the material bond between the base sheet and the insulation sheet may be so good that no further fastening provisions whatever need be made between the two sheets.
  • the insulation sheet may be provided with a textured surface to produce a form lock with the base sheet.
  • anchoring elements protruding past the back side of the insulation sheet into the insulation sheet. These anchoring elements are surrounded by the material of the base sheet and thus form a secure mutual anchoring of the two sheets once the base sheet has set.
  • recesses may be made, in particular milled, into the back side of the base sheet for receiving elements of a supporting structure and/or in the form of installation ducts.
  • the enclosed drawing illustrates three exemplary embodiments of wall elements according to the invention.
  • FIG. 1 a fragmentary cross section through a first wall element
  • FIG. 2 a fragmentary cross section through a second wall element
  • FIG. 3 a fragmentary cross section through a third wall element.
  • the wall element 10 of FIG. 1 has a composite of a base sheet 11 and an insulation sheet 12 . Both sheets 11 and 12 are made from plant materials. In the base sheet 11 , cement can be used as a binder, for instance.
  • the manufacture of the wall element 10 is done such that the material for the base sheet 11 is poured onto the back side 12 . 1 .
  • fastening anchors 13 are inserted into the back side 12 . 1 of the insulation sheet 12 .
  • these fastening anchors 13 which are surrounded on all sides by the material of the base sheet 11 , an optimal bond is created between the two sheets 11 and 12 .
  • recesses 14 On the inside 11 . 1 of the base sheet 11 , recesses 14 of approximately square cross section have been milled. Into these recesses, elements of a supporting structure, such as wooden posts, may be inserted.
  • the wall element 20 shown in FIG. 2 is also manufactured from a component of an insulation sheet 22 and a base sheet 21 , which are made from the same or a similar material as the sheets 11 and 12 .
  • the manufacture of the wall element 20 is likewise done by pouring the material for the base sheet 21 onto the back side 22 . 1 of the insulation sheet 22 .
  • the form lock between the base sheet 21 and the insulation sheet 22 is produced by providing the back side 22 . 1 of the insulation sheet 22 with a profile that is penetrated by the material of the base sheet 21 , creating an inseparable bond between the two sheets 21 and 22 .
  • recesses 24 have been made, which in this case have a cross section in the form of a double T and extend in terms of depth as far as the insulation sheet 22 . Supporting structure elements inserted into the recesses 24 can thus be secured directly to the insulation sheet 22 . Moreover, they are joined to the base sheet 21 by form locking, because of the cross-sectional shape of the recesses 24 . In addition, it is understood that fastenings to the base sheet 21 may be provided.
  • An installation duct 25 has also be milled into the base sheet 21 . Pipes and/or lines may be laid in this installation duct.
  • the wall element 30 shown in FIG. 3 like the wall element 10 , comprises a base sheet 31 and an insulation sheet 32 and is provided with recesses 34 for receiving wooden posts, not shown here.
  • the manufacture of the wall element 30 is different from that for the wall element 10 .
  • the material for the base sheet 31 is introduced into a mold. There are rods in the mold that act as positive-displacement bodies and thus lead to the creation of air chambers 35 in the base sheet 31 .
  • the material of the base sheet 31 placed in the mold is compacted.
  • a grid is also pressed onto the top side and results in the formation of air chambers 36 directly on the top of the base sheet 31 .
  • the insulation sheet 32 whose contact side toward the base sheet 31 has been moistened, is placed on the material of the base sheet 31 and optionally pressed against it.
  • the positive-displacement bodies Once the positive-displacement bodies have been poured out, air can be blown through the air chambers 35 , 36 , which reinforces the setting process.
  • the positive-displacement bodies can first be frozen as well. The ice melts in the setting process.
  • the resultant water like the water contained in the material for the base sheet 31 , is needed for the setting process.
  • the material of the base sheet 31 may also be mixed with clumps of ice, which melt in the setting process and leave small-volume air chambers behind.
  • the air chambers 35 and 36 shown in the example here are of relatively large volume, but they extend in the horizontal direction, so that no convection flow of the air can occur in them. They can therefore extend over the full width of the wall element 30 .
  • the air chambers have the advantage, because of the delivery of air in the manufacture of the wall elements 30 , that they increase the thermal insulation value of the entire wall element. They also assure a weight reduction and hence better transportability of the wall element 30 .
  • a form-locking bond as in the wall element 20 or bonding via anchoring elements as in the wall element 10 can be established, if that should be necessary for secure bonding between the insulation sheet 32 and the base sheet 31 .
  • elements 10 , 20 and 30 can also be made without the recesses 14 , 24 and 34 and without installation ducts 25 and can be furnished as a semifinished product to carpentry shops or prefabricated home-building businesses. These facilities then put a plurality of these wall elements together, making complete building walls, and also make the required recesses in the base sheets. Next, the elements of the supporting structure are inserted into the recesses and secured. After that, the back sides 11 . 1 and 21 . 1 of the base sheets 11 , 21 , 31 can be provided with cover plates, such as plaster plates. The outsides of the insulation sheets may be provided with a foundation plaster. The thus-completed building walls are then transported to the construction site, where they are set up and joined together.
  • buildings can be made that combine the advantages of solidly built buildings with those of prefabricated homes.
  • the wall construction itself is solid.
  • the entire building can be prefabricated industrially as is done for prefabricated homes.
  • similarly fast setup times for the buildings can be assured.
  • the wall elements of the invention have the advantage that with them, buildings open to diffusion with high thermal insulation can be manufactured.
  • the wall elements can be made entirely of renewable resources and can thus be 100% recycled.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Civil Engineering (AREA)
  • Building Environments (AREA)
US10/549,073 2004-03-16 2004-03-16 Wall element Abandoned US20070051061A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2004/002700 WO2006021222A1 (de) 2004-03-16 2004-03-16 Wandelement

Publications (1)

Publication Number Publication Date
US20070051061A1 true US20070051061A1 (en) 2007-03-08

Family

ID=35967172

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/549,073 Abandoned US20070051061A1 (en) 2004-03-16 2004-03-16 Wall element

Country Status (3)

Country Link
US (1) US20070051061A1 (de)
EP (1) EP1664452A1 (de)
WO (1) WO2006021222A1 (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060096214A1 (en) * 2002-09-10 2006-05-11 Herbert Groschup Construction system for erecting buildings
US20070256387A1 (en) * 2006-04-07 2007-11-08 Dorsy Sean C Multi-tiered, expandable panel structures and methods of manufacturing the same
US20080236084A1 (en) * 2007-03-26 2008-10-02 Pontarolo Engineering S.P.A. Disposable casing for thermally insulated walls in reinforced concrete
US20120011793A1 (en) * 2010-07-17 2012-01-19 Earthcore Worldwide, Inc. Adhesion Enhanced Insulated Framing Member
US9249572B2 (en) 2010-10-11 2016-02-02 Michael Neumayr Prefabricated shear wall system with integrated channels

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4274239A (en) * 1976-09-03 1981-06-23 Carroll Research, Inc. Building structure
US20010045071A1 (en) * 2000-04-19 2001-11-29 Budge Paul William Concrete composite non-meshed wall finishing system over key lock grid substrated
US6355333B1 (en) * 1997-12-09 2002-03-12 E. I. Du Pont De Nemours And Company Construction membrane
US20040065033A1 (en) * 2001-02-21 2004-04-08 Alexander Bleibler Prefabricated construction element for buildings

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1409944A1 (de) * 1962-07-17 1969-01-16 Schaller Dipl Ing Hans Schall- und waermedaemmende Bauplatte
GB1440201A (en) * 1973-08-10 1976-06-23 Okutani K Structural board
DE3121849A1 (de) * 1981-06-02 1982-12-30 Mathias 8229 Piding Reichenberger Putztraeger-isolierplatte
FR2507647B1 (fr) * 1981-06-10 1986-05-02 Borghese Louis Panneau de construction prefabrique et procede pour la realisation d'un tel panneau
AT370470B (de) * 1981-06-24 1983-04-11 Oesterr Heraklith Ag Mehrschicht-daemmplatte und verfahren zu ihrer herstellung

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4274239A (en) * 1976-09-03 1981-06-23 Carroll Research, Inc. Building structure
US6355333B1 (en) * 1997-12-09 2002-03-12 E. I. Du Pont De Nemours And Company Construction membrane
US20010045071A1 (en) * 2000-04-19 2001-11-29 Budge Paul William Concrete composite non-meshed wall finishing system over key lock grid substrated
US20040065033A1 (en) * 2001-02-21 2004-04-08 Alexander Bleibler Prefabricated construction element for buildings

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060096214A1 (en) * 2002-09-10 2006-05-11 Herbert Groschup Construction system for erecting buildings
US20070256387A1 (en) * 2006-04-07 2007-11-08 Dorsy Sean C Multi-tiered, expandable panel structures and methods of manufacturing the same
US7803467B2 (en) 2006-04-07 2010-09-28 Dorsy Sean C Multi-tiered, expandable panel structures and methods of manufacturing the same
US20110011025A1 (en) * 2006-04-07 2011-01-20 Dorsy Sean C Expandable Panel Structures And Methods Of Manufacturing The Same
US8084141B2 (en) 2006-04-07 2011-12-27 Dorsy Sean C Expandable panel structures and methods of manufacturing the same
US20080236084A1 (en) * 2007-03-26 2008-10-02 Pontarolo Engineering S.P.A. Disposable casing for thermally insulated walls in reinforced concrete
US20120011793A1 (en) * 2010-07-17 2012-01-19 Earthcore Worldwide, Inc. Adhesion Enhanced Insulated Framing Member
US9249572B2 (en) 2010-10-11 2016-02-02 Michael Neumayr Prefabricated shear wall system with integrated channels

Also Published As

Publication number Publication date
WO2006021222A1 (de) 2006-03-02
EP1664452A1 (de) 2006-06-07
WO2006021222A8 (de) 2006-04-27

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STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION