WO1997015744A1 - Shaped bodies, their production and their use - Google Patents

Abstract

The invention concerns a shaped body (1) for use in the building industry, the shaped body being formed in that at least one section (2) of a rock wool plate (7) is provided with a synthetic resin coating (8, 9) which partially penetrates the rock wool plate (7). In order to obtain a high-quality surface, the coating can be provided with a filler material such as, for example, cement, resulting in good workability of the surface. The shaped body can also comprises strengthening elements, for example, metal reinforcements, which give the shaped body good load carrying ability. This method produces shaped bodies which have a high degree of heat insulation and a pleasant appearance and can be used as windowsills or facade-cladding elements, for example.

Description

 Shaped body and manufacture and use thereof

Technical field

The invention relates to a shaped body according to the preamble of claim 1 or 5. Furthermore, the invention relates to methods for producing such shaped bodies according to claims 10 and 17 and uses of such shaped bodies.

State of the art

From US-A-4 553 364 it is known to create a window sash and window frame from a shaped glass wool body which is provided with a synthetic resin coating. An outer layer of the molded body is formed, which consists of glass wool soaked with the synthetic resin. Although these special shaped bodies shown have good thermal insulation, they do not satisfy on the one hand because the surface formed from glass wool material and synthetic resin is uneven. These shaped bodies require extensive further processing, e.g. a metal or vinyl cladding mentioned in this document if aesthetically pleasing surfaces are to be produced. There is also the risk that new thermal bridges will be created again.

The shaped body shown as a window frame in US Pat. No. 4,553,364 can also be used only to a limited extent as a load-bearing component, since it cannot cope with larger loads.

Presentation of the invention

The invention is therefore based on the one hand the task of creating a shaped body in which, in addition to good thermal insulation, a high-quality surface can also be achieved in a simple manner. This object is achieved with the characterizing features of claim 1.

It has been shown that by providing a filler in addition to the coating material, a high-quality surface can be achieved in a simple manner. The filling material can close all pores of the insulating material so well that there is a coherent, easy-to-work surface that can be easily processed using conventional surface treatment, e.g. made possible by grinding and painting, which cannot be carried out in this simple manner in the molded article according to the prior art. The processing can be done with woodworking machines. In particular, fiber insulation materials are suitable as the insulation material, e.g. Stone wool, glass wool, coconut fiber boards, but also textile fiber boards, as well as non-fibrous insulating materials with pores, e.g. sheets pressed from cork or foam glass.

The molded body is preferably also formed such that the coating is formed from at least two layers, of which the outermost layer contains the filler material. This allows the production of particularly stable, yet aesthetically high-quality molded articles in a simple manner.

There is also the task of creating a shaped body of the type mentioned, which is suitable for higher loads.

This object is achieved by a molded body with the characterizing features of claim 5.

By means of a reinforcement embedded in the coating, a shaped body can be created which, in addition to the high thermal insulation, can withstand high loads and is suitable for corresponding applications.

The reinforcement is preferably designed as a metal reinforcement or reinforcement. Non-metallic reinforcement or reinforcement can also be provided. It is further preferred if the moldings mentioned are formed from at least a section of a stone wool insulation board and are coated with a hardening synthetic resin. There is also the task of creating processes for the simple production of the moldings mentioned. This is achieved for the shaped body according to claim 1 with the method according to claim 11. For the molded body according to claim 5, this is achieved with the method according to claim 17.

Preferred uses for the molded article with filler material and high-quality surface are visible building elements. The shaped bodies provided with a reinforcement element, on the other hand, are preferably used as load-bearing and generally invisible components of a building.

Brief description of the drawings

Exemplary embodiments of the invention are explained in more detail below with reference to the figures. It shows

FIG. 1 schematically shows a perspective representation of a shaped body which is designed as a window sill;

Figure 2 also schematically in perspective a molded body, which as a load-bearing component, e.g. is designed as a lintel or lintel;

FIG. 3 shows a cross section through a molded body according to FIG. 1, only partially shown; and FIG. 4 shows a cross section through a molded body according to FIG. 2, which is also only partially shown.

BEST WAY OF IMPLEMENTING THE INVENTION FIG. 1 shows, roughly schematically, a molded body 1, the outer shape of which is formed by the composition of several sections 2, 3 and 4 of a fiber insulation material. forms are. A groove 5 is also incorporated in section 2. In this form, the molded body could form a window sill, for example. Sections 2, 3 and 4 consist of sections of mineral fiber boards, in particular rock wool boards. Rock wool panels are commercially available components which are produced by pressing together a large number of long rock wool threads with a binder. Such rock wool panels are available under various trade names and are used for a variety of insulation purposes, especially in the building industry. The molded body now consists of at least one section of such a commercially available rock wool plate, the molded body being composed of three such sections 2, 3 and 4 in the example according to FIG. 1. The composition can be created, for example, by gluing sections 3 and 4 to section 2 or by mechanical anchoring means which hold the sections together. Instead of the rock wool mentioned as a preferred example, the sections could also consist of other fibrous or non-fibrous insulating materials, of which some examples have been mentioned at the beginning. The molded body 1 is now further formed in that the mineral fiber or rock wool material is provided with a coating. This is preferably a synthetic resin coating which is applied in liquid form to all surfaces of the rock wool body. The liquid coating then partially penetrates the rock wool body and hardens in a known manner. The result is a stable molded body which consists essentially of rock wool and has only a thin surface coating made of the hardenable material. A filling material is now added to the coating material, which largely forms the actual surface of the molding. The filling material fills the pores and cavities of the relatively coarse rock wool slab in addition to the coating material, so that after the coating material has hardened, rials easily machinable surface of the molded body arises. In particular, the surface of the shaped body formed in this way can be processed by milling and / or grinding and, if necessary, applying a filler in order to obtain a high-quality, smooth surface. The groove 5 can be grooved again after the coating, for example, in order to maintain a perfect surface here as well.

The stone wool slab mentioned can be commercially available stone wool slabs with a density of, for example, 130 kg / m ³ . The molded body can also be composed of differently layered plates. In addition to or instead of sections made of stone wool material, sections made of glass wool, coconut panels or other fibrous or non-fibrous insulating material can of course also be used in any combination, as mentioned. The density of the panels can also vary widely.

In principle, any curable material that can penetrate into the plate material in liquid form is suitable as the coating material. Exemplary embodiments with synthetic resin as coating agent are mentioned below, this being understood only as an example. In particular, the products referred to as binders (see, for example, Römpp Chemie Lexikon, 9th edition 1989, volume 1, pages 416/417) are suitable as coating material. Depending on the type of use of the shaped body, the person skilled in the art will select a suitable binder. If, for example, low flammability or non-flammability of the molded body is important, a non-flammable or hardly flammable binder, for example an inorganic, mineral binder, can be used as the coating material instead of synthetic resin. The setting time of the respective binder can be controlled by its composition or by additives, which is known in principle and is not explained in more detail here. that must. Filling material is also added to an inorganic coating material in order to achieve a good surface finish and, for example, to enable good processing by grinding. The filling material can also be selected from a wide range of materials. In addition to the preferred materials cement and sand, for example wood sawdust or metal powder can also be used, as a result of which a different surface quality and workability than cement or sand can be achieved.

The molded body composed of several sections in FIG. 1 can also be produced in such a way that first the individual sections 2, 3 and 4 are formed individually from insulating material with a coating and filler material and are only assembled to form the molded body 1 after they have hardened become. However, the composition of the as yet uncoated sections of the shaped body is generally preferred.

The shaped body is preferably also provided with not only one coating layer, but with at least two layers. This is shown roughly schematically as an example in FIG. 3, which shows a cross section, for example, through the shaped body of FIG. 1. In FIG. 3, the two layers are differentiated from one another by various graphic means of illustration, but it should of course be emphasized that, depending on the method of production, which will be described below, the individual layers in the real molded body cannot be perceived as separate from one another. FIG. 3 shows part of an insulation board, for example a stone wool board 7, which is initially provided with a first layer 8 penetrating into the stone wool board and with a second layer 9 which also also penetrates into board 7. Second layer 9 contains this Filling material. The surface of the body is thus formed by filling material, coating material and rock wool threads. In the following, the production of a shaped body of the type previously described will be explained as an example. First, a commercially available insulation board, for example a stone wool board of the desired thickness, is cut to a shape that corresponds to the desired shape of the molded body. The plate can be further processed, for example by introducing a groove 5, as shown in FIG. 1. The molded body can further be brought into the shape which essentially corresponds to the desired shape by adding additional sections which are formed from stone wool slab pieces. In Figure 1, this is shown by sections 3 and 4 as an example. These sections can be attached to the base plate in any way. This is followed by a first coating of the rock wool shaped body thus formed with a coating material. Preferably, a commercially available synthetic resin is used, for example a commercially available epoxy or polyester synthetic resin. A first coating is preferably applied in which the synthetic resin is relatively thin, so that the synthetic resin penetrates well into the rock wool body. A penetration of several millimeters into the stone wool slab can be achieved, whereby the penetration depth along the slab can of course be different. The depth of penetration can also vary depending on the type of fiber material. A second resin layer, which is provided with the filling material, is then preferably applied subsequently before the curing of this first synthetic resin layer. This resin layer also penetrates the stone wool plate, the filling material, however, more or less closing the pores of the stone wool plate depending on the amount of resin applied, so that a relatively smooth surface is formed. The penetration of the second coating can also take place a few millimeters, whereby, of course, since the first layer has not yet hardened, mixing of the two layers occurs. can. However, the filler material is mainly found in the upper area of the resulting overall coating, since the filler material cannot penetrate deep into the stone wool slab. The amount of the filler material added to the synthetic resin can be chosen in a wide range, this of course taking place depending on the unevenness of the stone wool slab. A very coarse-grained rock wool board or coconut fiber board with large unevenness will make it necessary to add a larger amount of filler material than the amount of synthetic resin in order to even out the unevenness and pores of the fiber material as well as possible. An addition of 5-70 parts by weight of filler material to 100 parts by weight of synthetic resin is entirely possible, an addition of approximately 10-50 parts by weight is preferred when working with cement as filler material. In the case of other filling materials or other coating materials, it may be possible to change these proportions. After the two coatings have been applied, the molded body is cured, which may take different time depending on the type of coating material used. With a known commercial epoxy resin, curing can be achieved in 15-20 minutes at a temperature of 60 ° or curing in 4-6 hours at room temperature. Instead of the two layers mentioned, it is of course also possible for only one coating, then directly with filler material, or more than two coating steps to be provided, generally only the last coating step being carried out with the filler material. It is also possible for a first layer to be cured first before the next layer is applied. But that is preferred

Wet-on-wet work without prior curing of the previous layer. After the shaped body has already hardened and already has a very good surface quality, further processing can be carried out using various processing methods. techniques, for example with woodworking machines and, if necessary, fillers with filler and sanding. The groove 5 is also reworked, for example by grooving, grinding, etc. Then, if desired, a cover can be applied, for example a paint with a commercially available paint or a paint with a sand-based paint or, for example, a spray coating with quartz sand, which can give the molded body a granite imitation surface. As a rule, the molded body will be coated over the entire surface; However, it is entirely possible to provide the coating with only a part of the molded body surfaces. If the body is coated over the entire surface, this molded body already has a good load-bearing capacity, which is sufficient for non-load-bearing and only slightly loaded load-bearing components.

The molded body produced in this way can be further processed in any manner. It is adhesive, can be screwed or nailed and can be cut by sawing. The use of such shaped articles is varied. Window sills or window frames can be formed. A lintel or lintel can also be formed in this way. A further good application possibility lies in the base elements of facade claddings, in particular those that reach into the ground.

Figure 2 shows an embodiment according to another aspect of the invention. Here again, a shaped body 10 is shown roughly schematically, which in this example is formed from two insulation boards lying one on top of the other, for example fiber insulation boards, in particular rock wool insulation boards 12 and 13. However, it can also be plates made of a non-fibrous material. The plates are cut to the desired shape and, for example, glued to one another or otherwise attached to one another. This molded body is also provided with a coating penetrating the rock wool. hen, which in turn is, for example, a synthetic resin coating or a coating with an inorganic binder, which will be explained in more detail below with reference to FIG. 4. In order to make the molded body suitable for larger loads, at least one reinforcing element is provided. In the example shown, rods 15, 15 'and 15 "are provided on the top of the molded body in the longitudinal direction of the molded body, which act as reinforcement elements. These reinforcement elements in the form of reinforcement or reinforcement can be placed on the rock wool plate or arranged in depressions thereof The rod 15 is preferably fastened with fastening means, only one bracket 20 being shown as an example in Figure 2. Of course, a plurality of such fastening means would be provided for the rods 15. The rod can, however, also be fastened without A special fastening means is used if the rods are inserted into depressions in the stone wool plate, which were produced by machining the stone wool plate, and the rods can be fastened at most even if the rods are only placed on or slightly pressed into the stone wool , if that is still to be explained coating provides sufficient strength for the intended application. In addition to the reinforcement bars 15 shown, such bars can of course also be provided on the underside of the element, which is indicated by the bars 16, 16 * and 16 "in the figure. It is clear that the The reinforcement shown by means of rods represents only one example of possible reinforcements or reinforcement elements. Instead of the rods, other elongate reinforcement elements can also be provided or, for example, lattice-shaped reinforcement elements can be provided. It is also possible, for example, that only one reinforcement element is larger

Cross-section, for example a hollow profile, is arranged in the longitudinal direction in the central axis of the molded body 10. The j e- the reinforcing element can be made of metal, for example. A reinforcing element made of wood is of course also possible, and plastic or possibly a reinforcing element made of cement or concrete is also possible. A special embodiment of the reinforcing element would be seen if one or more longitudinal grooves were milled or cut into the plate 13 which are then completely or partially filled with a hardening material, such as cement or synthetic resin, so that there is a reinforcement integrated into the molded body. On the face side, the grooves to be filled, which are mentioned as examples, can be closed with a plate or a stopper during the casting operation, or the groove may not extend all the way to the face side, so that grooves are formed on the face side, into which the reinforcement can be made without further measures forming mass can be poured.

The reinforced molded article is also coated with a coating compound penetrating into the molded article. In the case of a reinforcement applied, a first coating can be carried out before the reinforcement is applied and a second coating after the reinforcement has been applied. However, the procedure can also be such that the reinforcement is first applied and then the one or more layers are applied. The reinforcing elements are at least partially, but preferably completely, covered by the single- or multi-layer coating. Since the coating penetrates the molded body, the reinforcing elements are generally enclosed on all sides by the coating material; in the case of reinforcements embedded in the molded body, the elements can be only partially enclosed or only covered on the top.

In this molded body with reinforcing element, too, synthetic resin is used for coating, for example turns and preferably again several layers of the coating material are applied, the first or the first layers being applied in a more fluid manner than the subsequent layers in order to achieve a good penetration of the coating material into the rock wool. In this embodiment, too, another of the materials already mentioned can of course be used instead of rock wool.

FIG. 4 shows an embodiment according to FIG. 2 in cross section, with two different layers 18, 19 also being distinguished in the drawing, which in reality, however, do not necessarily have to be exactly separated from one another, in particular when working wet-on-wet , as has already been explained in the manufacture of the shaped body of Figure 1.

A filling material can also be provided in the outer layer when producing a shaped body with reinforcing or reinforcing elements. As a rule, this will not be the case, since the outer layer formed in this way primarily serves the good machinability of the shaped body, which is generally only necessary if the shaped body is visibly inserted. In the case of the molded bodies provided with reinforcing elements, the focus is on the invisible use, for example as a lintel or door lintel or as another load-bearing component. As said, however, the filler material can also be used in the outer layer exactly as described in the previous examples, or reinforcement elements can also be used in the previously described embodiments with filler material in order to to give the respective component greater strength. If filler material is used and further processing of the surface, for example by grinding, is planned, it is preferred, however, if the reinforcing elements are recessed in the molded body so that the Further processing of the molded body is not disturbed by reinforcing elements protruding from the coating.

Claims

claims 1. Shaped body (1, 10) formed from at least one section (2, 34; 12, 13) of a pore Insulating material, the shape of which essentially corresponds to the desired shaped body shape and which is provided at least on one of its surfaces with a hardened coating material which has penetrated into the insulating material section, characterized in that the coating material forms the surface of the shaped body at least in its area Area is filled with a filler. 2. Shaped body according to claim 1, characterized in that the coating material is provided in at least two layers (8, 9), of which the outer layer (9) contains the filler material. 3. Shaped body according to claim 1 or 2, characterized in that the filling material is formed by cement and / or sand. 4. Shaped body according to one of claims 1 to 3, characterized in that the filler material makes up 5-70% by weight, preferably 10-50% by weight, of the coating material containing the filler material. 5. Shaped body (1, 10) formed from at least a portion of an insulating material having pores, the shape of which essentially corresponds to the desired shape of the shaped body and which is provided on at least one of its surfaces with a hardened coating material that has penetrated into the insulating material portion, characterized in that that a reinforcing element embedded wholly or partially in the coating is provided on at least one side of the molded body. 6. Shaped body according to claim 5, characterized ge indicates that the reinforcing element is formed by a rod-shaped or net-shaped reinforcement. 7. Shaped body according to claim 6, characterized in that the reinforcing element is made of metal. 8. Shaped body according to one of claims 1 to 7, characterized in that the section from a Fiber insulation board, in particular a rock wool insulation board is formed, or that the section of a non-fibrous insulation board, e.g. a cork shot plate or a foam glass plate. . 9. Shaped body according to one of claims 1 to 8, characterized in that the coating material is formed by a curing synthetic resin. 10. Shaped body according to one of claims 1 to 8, characterized in that the coating material is formed by an inorganic binder. 11. The method for producing a shaped body according to claim 1, characterized in that the desired shaped body shape is formed from a section of a fiber insulation board, in particular a rock wool board, or from several such interconnected sections, and that at least one quantity contains a filler material a coating material penetrating into the section is applied to the section. 12. The method according to claim 11, characterized in that first a first amount of a coating material penetrating into the section is applied without filler material and subsequently the coating material is applied with the filler material. 13. The method according to claim 12, characterized in that the first amount when applying the coating material is more liquid than the second amount. 14. The method according to claim 12 or 13, characterized in that the second amount is applied before the first amount has hardened. 15. The method according to claim 11 to 14, characterized in that after the hardening of the coating material or the coating materials, the shaped body is smoothed on its surface and provided with a cover. 16. The method according to any one of claims 11 to 15, characterized in that the proportion of filler is 5 to 70 wt .-%, preferably 10 to 50 wt .-%, the second amount of coating material. 17. The method for producing a molded body according to claim 5, characterized in that the desired molded body shape is formed from a section of an insulating board, in particular a rock wool board, or from a plurality of such interconnected sections that on at least one side of the section, at least one reinforcing element is placed or incorporated into the section, and that at least an amount of a coating material partially penetrating into the section is applied, which at least partially surrounds the reinforcing element. 18. The method according to claim 17, characterized in that a quantity of the coating material is applied even before the reinforcing element is placed on it. 19. The method according to claim 17 or 18, characterized in that the reinforcing element is fixed to the section with fastening means. 20. Use of a shaped body according to one of claims 1 to 4 as a visible component of a building. 21. Use of a shaped body according to one of claims 5 to 9 as a supporting component in a building.