The invention relates to a building wall.
WO 2017/0812 A1 discloses a method for producing a building with a plurality of walls. First, a flexible enveloping form is spread out at a predefined location. The flexible enveloping form is then filled with a foaming material which subsequently hardens, forming stable walls.
DE 199 50 139 A1 discloses a possibility for closing the spaces between the beams of a roof truss. The mechanical stability is sufficiently ensured by the beams. In this case, strips are attached to the beam by clamps and then filled with foam. A grid spacing between spacers is comparatively large at more than approx. 10 cm, which leads to a comparatively large deformation of the surface, but this is acceptable for the roof construction. The intermediate space delimited and to be filled by the sheets extends, for example, continuously from a foot purlin to a ridge purlin (Sp.1, Z. 11ff), which is usually a length of well over 2 metres in length. A similar construction is known from DE 35 02 323 A1.
A building wall (1), in particular a floor wall, roof wall or side wall, which is provided with a base frame (2) comprising a plurality of braces (21, 22), wherein the base frame (2) forms an intermediate space (23) between the braces, wherein the intermediate space (23) is filled by a foamed filling material (4).
It is an object to provide an improved building wall.
The object underlying the invention is solved by a building wall, a building and a method according to the main claims; embodiments are the subject of the subclaims and the description.
The invention comprises a building wall, which may be a floor wall, a roof wall or a side wall of a building. The wall has a base frame comprising a plurality of braces. The braces are in particular formed of wood. The base frame forms a space between the braces. The space is filled with a foamed filling material.
In one embodiment, the intermediate space is delimited, in particular next to the braces, by an enveloping form, which is in particular a textile form. In particular, the enveloping form delimits the intermediate space in a direction transverse to the wall plane, while the braces delimit the intermediate space in a direction parallel to the wall plane.
In particular, a plurality of spaces are formed between each other, each separated by a horizontal brace.
Each intermediate space can be provided with its own enveloping form, so that several enveloping forms arranged are provided one above the other for one wall.
Alternatively, a common first shell (outer shell or inner shell) can be provided for several intermediate spaces on at least one side. In the case of a common first shell on one side, the enveloping form is then placed around the braces starting from the side with the common first shell and attached to it from both sides. For this purpose, braces can be guided through passages between two adjacent second shells (outer shell or inner shell).
In an alternative embodiment, both the outer shell and the inner shell are designed to define a plurality of intermediate spaces together. In this case, individual braces are to be inserted through insertion channels of the pre-assembled enveloping forms. Then the enveloping forms can have continuous shells on both sides.
The subdivision of a wall into a multitude of intermediate spaces arranged one above the other favours the formation of homogeneously filled intermediate spaces. The height of a single intermediate space is thus limited by a horizontal brace. Consequently, a new intermediate space begins at each horizontal brace. A low total filling height is favourable for a homogeneously filled intermediate space. In particular, the height of an intermediate space of a side wall is max. 1.5m, especially max. 70 cm.
In one embodiment, the enveloping form comprises an outer shell defining the intermediate spaces on an outer side of the wall and an inner shell defining the intermediate space on an inner side of the wall.
In one embodiment, the outer shell and the inner shell are connected to each other by at least one connecting thread, in particular by a plurality of connecting threads. The connecting thread bridges the intermediate space in particular. In one embodiment, the enveloping form is prefabricated with the outer shell, the inner shell and the connecting thread.
In one embodiment the connecting threads are uniformly distributed over a length direction and a width direction respectively.
In one embodiment adjacent connecting threads in the length direction and in the width direction are at a distance from one another of max 5 cm, preferably max. 2 cm or 1 cm, and/or there is an average number of at least 100, preferably 200 or 400 connecting threads per square metre, preferably at least 1000 or 5000 connecting threads per square metre, in the intermediate spaces.
In an embodiment the base frame, in particular a brace of the base frame, comprises a filling opening for filling the filling material into the intermediate space.
In one embodiment, the enveloping form is attached to a brace of the base frame. In this case, the outer shell is fastened to an outer side of a brace of the base frame and/or the inner shell is fastened to an inner side of a brace of the base frame. The fastening is then in particular in such a manner that the braces at least partially limit the space to be filled for the filling material in the direction of the wall plane.
In one embodiment, two adjacent intermediate spaces within a wall are each delimited by two separate outer shells and/or each delimited by two separate inner shells. In this case, the adjacent intermediate spaces within a wall can each be delimited by two separate enveloping forms. Especially if prefabricated enveloping forms with connecting threads are used, it is not possible to limit several intermediate spaces by a common envelope without further ado, since the envelope has to be passed through the intermediate space in each case. Possibilities for solving this conflict are described within the scope of this application
In one embodiment, a common brace is arranged between the two adjacent intermediate spaces. The two separate outer shells and/or inner shells are attached to the common brace.
In one embodiment, a wall, in particular the base frame of the wall, comprises several intermediate spaces between each other. The intermediate spaces are each separated from each other by a common brace. The multiple subdivision of a wall creates several small intermediate spaces that are to be filled separately. Tests have shown that a foam quality of plastic foam that meets the high requirements for wall or roof elements in terms of strength, impermeability and thermal conductivity can be achieved in particular if the size, especially the height, of the respective intermediate spaces to be filled is comparatively small. Furthermore, additional braces create improved stability and dimensional stability of the base frame and thus of the finished wall.
In one embodiment, the wall is a floor wall that is arranged on a, particularly uneven, ground. The intermediate space is at least indirectly delimited on the floor side by the ground. A foil can delimit the intermediate space on the underside and, in particular, rest on the floor. The advantage is that no substantial preparatory work is required on the ground. The foil can be applied to the untreated ground and any unevenness is automatically levelled out by the filling material. The foil prevents any material interaction between the ground and the filling material.
In one embodiment—especially for the bottom wall—the intermediate space is filled in layers by several quantities of filling material. By filling in layers, the quality of the foamed material can be improved. In particular, the material has a homogeneous density distribution and an otherwise occurring detachment of the filling material from the wall during curing is prevented.
In one embodiment, the intermediate space is delimited on the upper side by a planking, in particular wherein the planking comprises a plurality of holes for the introduction of filling material. The planking forms a defined closure of the intermediate space at the top so that the floor is widely flat at the top. In particular, the planking is already connected to the intermediate space when the filling material is filled, so that it is to be regarded as a component of the mould. The holes in the planking serve to let in the filling material, in particular in a small quantity required to completely fill the intermediate space.
The invention further relates to a building having a plurality of walls of the aforementioned type.
The invention further relates to a method for manufacturing a wall of the aforementioned type, comprising the following method steps: Providing the base frame;
fixing the enveloping form to the base frame;
filling the intermediate space with at least a quantity of filling material, wherein the filling material foams up after filling.
In one embodiment, a prefabricated enveloping form is used, whereby the inner shell of the enveloping form is connected to the outer shell of the enveloping form by the connecting threads before the enveloping form is attached to the base frame. This allows for easy assembly of the enveloping form on site, as only the prefabricated elements need to be inserted and fastened.
In one embodiment, the enveloping form is at least partially passed through the intermediate space. Further, the outer shell of the enveloping form is attached to a brace on the outside of the wall and an inner shell of the enveloping form is attached to the brace on the inside of the wall. This method allows the inner and outer shells, which are firmly attached with the connecting threads, to be attached to the prefabricated base frame.
Fixing the inner shell and/or the outer shell to the brace can be done by a sealing layer—for example adhesive tapes, elastic or pasty sealing materials—and clips shot into the brace. This is a simple and stable method and does not require any special tools.
In one embodiment, the outer shell and/or the inner shell is urged against the brace with a fastening fitting for fastening. In particular, the outer shell or inner shell is consequently clamped between the fastening fitting and the brace, which enables reliable fastening and sealing. The fitting is in particular arranged circumferentially around the intermediate space, whereby the fitting can also be an arrangement with several individual fitting parts (the fitting does not have to be a one-piece and all-round closed individual fitting part).
In particular, the following underlying conditions must be taken into account:
When foaming out filler material, especially with foam plastics such as polyurethane, polystyrene, PIR (polyisocyanurate), etc. only a limited amount of foam material can be introduced into the intermediate space in the time available “for one shot”. Therefore, the individual intermediate spaces are comparatively small in size. If a lot of filling material is inserted at the same time, the reaction heat in the intermediate space can cause overheating, which can damage the frame, the filling material or other elements.
The wall should preferably support the mechanical load-bearing capacity in addition to thermal properties of the wall. The base frame can therefore be manufactured much more cost-effectively. For mechanical strength, it is advantageous if the foam forms a direct material bond with the base frame. This is made possible by applying high pressure during production.
Preferably, a defined pressure of the filling material is achieved in the intermediate space. For this purpose, a precisely calculated amount of filling material is filled into a defined intermediate volume, which hardens to a foam of defined density.
High pressure is also beneficial for
The build-up of the required pressure and the limitation of the filling material, which is especially introduced once, requires an intermediate space of defined size that is closed on all sides. Furthermore, overflowing of the foam into the adjacent chamber during foaming must be avoided, as otherwise the pressure is not set correctly and, if necessary, filling material can flow into adjacent intermediate spaces and foam up there in an uncontrolled manner.
Intermediate spaces with a large dimension in length or width (side length>1.5 m) tend to cause the curing filler material to change the shape of the base frame due to shrinkage (e.g. warping it inwards), especially if foamed with the wrong pressure. Therefore, sealing and stiffening braces, especially horizontal braces, are inserted at regular intervals (e.g. approx. 0.5 to 1 m) in order to keep the side length of the intermediate space small and to limit the bending.
The foam material is in particular of low viscosity in order to fill the intermediate space optimally. Since the low viscosity continues during foaming or shortly thereafter, the intermediate space must be completely sealed.
Preferably, the inner shell and the outer shell are bonded to the base frame, in particular by means of double-sided adhesive tape or elastic or paste-like sealing materials.
Preferably, the filling of the intermediate spaces takes place through an opening in the base frame or through a raised edge of the enveloping form.
Subsequently, the openings are closed, for example, by plugs or the lifted-off areas are sealed, in particular with clips, especially with wooden or metal strips during the foaming phase
Preferably, ventilation openings (e.g. holes) are provided in the upper corners to allow the air in the element to escape. Otherwise, the intermediate spaces in the upper area cannot be filled completely.
The advantages and embodiments mentioned with regard to the method and the apparatus are also applicable to the device and the method.
The invention is explained in more detail below with reference to the figures; herein shows:
Intermediate spaces 23 are formed between the braces 21, 22, into which a foaming filling material is filled in the course of the manufacture of the wall.
The wall should be constructed in such a way that the filling material provides an essential part of the stability. The base frame can be so small that the required load-bearing capacity of the wall is not provided solely by the frame. The frame can therefore be constructed much more cheaply than, for example, a wall that is produced by classic carpentry using a wooden frame.
In order to provide the load-bearing capacity of the wall mainly through the filling material, the filling material is to be introduced into the intermediate space in such a way that a high pressure of at least 1.2 bar (overpressure) is created in the intermediate space during foaming. In particular, the filling material permanently generates an especially considerable pressure on the outer shell and on the inner shell of at least 1.2 bar overpressure, even in the cured state. In order to favour this, a number of further features are advantageous:
During filling, the amount of filling material is of great importance, as it is decisive for the generation of the advantageous minimum pressure during curing. Thus, it is advantageous for stability if a quantity of filling material is filled as precise as possible into the intermediate space. The density of filling material in the intermediate space is used as the target parameter, which can vary for different applications and materials. For example, if a density of 50 kg/m3 (cubic metre) is required to form a solid wall. From this, taking into account the volume of the intermediate space, the exact amount of filling material to be filled into the intermediate space can be calculated. Now the filling is done with exactly the calculated amount of filling material. The optimum pressure of the filling material, in particular at least 1.2 bar during curing, is then automatically set.
The large number of connecting threads per unit area can be seen in
A distance between two adjacent connecting threads in the length direction y and in the width direction y is in particular max. 5 cm, in particular max. 2 cm. In particular, at least individual connecting threads have a distance to each other of max. 10 mm.
The intermediate spaces are comparatively small. This is the only way to achieve uniformly high pressures in the filling material, dimensional stability and sufficiently low reaction temperatures. The side length of the intermediate space, i.e. the length (in x-direction) of an intermediate space 23, and the width (in y-direction) of an intermediate space 23 is max. 1.5 m, preferably max. 1.2 m.
Such enveloping forms 3 can be prefabricated. For assembly, the enveloping form 3 is to be passed partially through the intermediate space 23 from one side. Therefore, each enveloping form is only used to delimit a single intermediate space 23.
A further enveloping form 3b is now attached to the braces to which an enveloping form is already attached. If there is still enough adhesive tape left, the other enveloping form can also be attached with this adhesive tape. Otherwise, a further second double-sided adhesive tape 57b is applied to the first enveloping form 3 in the area of the braces, by means of which the further enveloping form 3b is fixed to the braces. For permanent fixing, a circumferential fastening fitting 58 is applied to the enveloping forms in the area of the braces, which in particular is fastened to the braces separately, i.e. in addition to the adhesive tape. This can be done by a screw connection 59 to the braces (
However, this overlapping arrangement of the enveloping forms in the area of the braces is not necessary. The enveloping forms can also be attached next to each other on a common brace, provided there is sufficient space therefore. Then two adjacent enveloping forms can also be attached to the common brace with a shared adhesive tape or with two separate adhesive tapes.
Then the space 3 is filled with the foaming filling material 4 (
The inner shell and the outer shell are then attached to the braces as previously described.
The inner cover and the outer cover are then attached to the braces as previously described.
A foil 52 is laid on the ground 91. Several ground anchors 51 are inserted into the ground (
Such a ground anchors 51 may comprise a threaded rod fixed to the ground.
A grounding fitting 53 is attached to each tie rod 51 by means of a grounding fixing 54 (
Intermediate spaces 23 are now formed between the braces 21, 22, which are subsequently filled with foaming filler material. Excess foil can be cut off (
Now the filling process is started (
A second amount of filling material is then introduced into the intermediate space 23 (
The above process can now be repeated as often as desired (
Now the intermediate space 23 is covered at the top with a planking 55. The planking 55 has holes 56 of about 10 mm diameter each at regular intervals of about 40-80 cm.
Small final quantities of filler material 44 are now introduced through these holes 56 (
Number | Date | Country | Kind |
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10 2020 107 069.1 | Mar 2020 | DE | national |
This application is the U.S. national stage of International Application No. PCT/EP2021/056436, filed on 2021 Mar. 13. The international application claims the priority of DE 102020107069.1 filed on 2020 Mar. 14; all applications are incorporated by reference herein in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/056436 | 3/13/2021 | WO |