CN104471159A - Construction element for walls and wall linings and method for producing the element - Google Patents

Abstract

A construction element for walls and wall lining, comprising at least one layer of lining material (11) and a layer of lightened natural lime (12) attached to said lining material (11) by drying to form a single body.

Description

Construction element for walls and wall linings and method for producing the element

field of invention

The invention relates to building elements for walls and wall linings and to a method for the manufacture of the elements. DE10160665 represents an example of a building element whose characteristics are described in the preamble of claim 1 .

Background of the invention

Natural lime is considered a natural hydraulic lime mortar. It is obtained by firing marl limestone in vertical ovens at a temperature of about 1000°C. A long quenching and aging takes place before grinding. When laying, it is sufficient to mix lime powder with water until a homogeneous, soft and lump-free paste is obtained.

In recent years, natural lime has been abandoned in favor of new materials that are easier to lay and more durable, as obtained by plasticizing the components.

In recent years, natural lime has been re-evaluated for a number of reasons.

First of all, natural lime, as its name indicates, is a natural product known since ancient times, of which we have established a certain confidence in its non-toxicity.

Second, natural lime is breathable, thus preventing the accumulation of moisture that can make the environment unhealthy.

Another reason lime is used more often has to do with its fire resistance. In fact, it has a fire resistance class 1, ie it is classified among the less combustible materials.

Furthermore, natural lime has a very poor thermal conductivity of about 0.54 W/mK.

Above all, thanks to this latter property, lime is used more and more often to produce thermal linings, ie external linings for dwellings, in order to reduce the conductivity of the walls being coated. For this purpose, it is often mixed with aggregates having insulating properties such as granular cork, natural or artificial fibers such as polystyrene and the like. By virtue of these blends, limes so composed are often referred to as "lightened" because these aggregates generally have a lower specific gravity than lime.

However, the use of lightened lime is laborious since it needs to be dried at optimum setting conditions for at least 24 hours and because the thickness of each spread layer cannot exceed 2 cm. Drying times can be further increased during winter.

Furthermore, unsightly depressions and protrusions often form on vertical walls when attempting to lay more than 2 cm at a time.

For example, an insulated external cladding could provide for laying as much natural lime as 8cm. This means that at least 4 layers must be generated.

It must also be taken into account that natural lime does not have great mechanical strength, so provision must be made to lay at least one mesh in order to prevent the formation of cracks and edge cracks. Furthermore, the effects of wind and bad weather generally tend to degrade the lime's most superficial layers very quickly.

Summary of the invention

The object of the present invention is to provide a construction element for walls and wall linings which allows to obtain the advantages of natural lime while minimizing its disadvantages, including its laborious laying and low mechanical strength.

According to claim 1, the object of the invention is a construction element for walls and wall linings.

Another object of the invention is a sandwich curtain wall element substantially obtained by the construction element described above with the addition of another inner lining in the free face of the lightened natural lime layer.

Another object of the invention is to show a method of producing said lining element which allows obtaining said element very quickly with uniform properties both in terms of form and finish.

Another object of the invention, according to claim 9, is a method of producing a lining element for a wall.

The dependent claims describe preferred embodiments of the invention and form an integral part of the present description.

Brief description of the drawings

Further characteristics and advantages of the present invention will become more apparent from the detailed description of a preferred but not exclusive embodiment of a lining element for walls exemplified by way of non-limiting example with the help of the accompanying drawings, in:

Figure 1 represents a cross-sectional view of the thickness of a building element according to the invention;

Figure 2 represents a variant of the building element according to the same view of Figure 1;

Figure 3 shows a further variant of a building element according to the same view of Figure 1;

FIG. 4 shows another variant of the building element according to the same view of FIG. 1 .

In the drawings, the same reference numerals and letters identify the same elements or components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

According to the invention, the lining element 1 comprises a first layer 11 of lining material intended to stay within the field of vision and at least a second layer 12 of lightened lime. see picture 1.

According to a first embodiment of the invention, said first layer is made of so-called thin stone. Thin stone consists of very thin sheets of solid stone supported by layers of resin, where thin means from a fraction of a millimeter to a few millimeters.

This thin stone layer is obtained by gluing a layer of resin, possibly supported by a network of fiberglass, to the surface of natural stone ridges such as sandstone, volcanic stone, quartzite, etc. As the resin dries, the thin layer of stone is completely torn from the ridge due to the mesh attached to the resin. Thus, the thin slab of stone obtained does not have a perfectly smooth surface, but instead it has a natural roughness due to its removal from the other layers of the ridge.

The use of thin stone has been known for some time, but has generally been associated with a support structure bounded by aluminum panels, usually hollow on the inside, with honeycomb-like cavities.

Dry lime provides the necessary support for the lining. In particular, according to the invention, the attachment of the lime to the inner liner preferably takes place due to the lime's own adhesive capacity. The lime thus naturally attaches to the inner liner when dried.

According to the invention, the thin stone is supported by a layer of lightened natural lime with a variable thickness between 1 cm, 10 cm, 20 cm, 30 cm, 40 cm or more depending on requirements.

Hereinafter, the word lime or natural lime indicates lightened natural lime.

Regarding the thickness of the lime layer, one or more withholding nets 13 may be introduced into the lime itself. See Figure 2 for this purpose. The mesh 13 is known per se. It can be made of plastic or fiberglass.

According to a preferred production process, the thin stone layer is usually laid horizontally onto the load-bearing surface and the natural lime is placed thereon, with the possible introduction of a barrier mesh 13 .

Thus, the thin stone slab has a natural stone face and a resin-coated face.

Regarding the surface roughness of the resin-coated face, it can be provided that a suitable fixing agent is used before the lime is laid.

For example, preferred fixatives may be made of polyurethane, of epoxy resin, possibly of two components.

When the lime has been applied, it can all be left to air dry or kiln dry. According to the invention, the obtained slabs can then be cut to specific requirements, forming bricks or slabs in relation to final dimension ratios.

Since, contrary to what might be believed, thin stone slabs can have a certain flexibility, the resulting building elements can exhibit discrete curvatures of the visible portion, which can be concave or convex.

According to a second variant of the invention, said first layer is made of tuff, ie natural limestone.

Tuff is a particularly brittle material, but has excellent properties related to its ability to insulate and store heat.

Such material is used in large quantities, however, due to its fragility it is quarried from very large blocks into thickset blocks having a thickness of not less than 5cm-7cm.

In order to coat walls with tuff, it is therefore necessary to use a considerable amount of material, taking into account the difficulty of working with this material. This means significant quarrying costs, cutting costs and transport costs, as well as laying costs.

According to the invention, said first layer 11 of construction elements may be made of tuff. The lime layer 12 provides a sufficiently rigid support that prevents the tuff from being crushed during laying and during handling of the obtained construction elements.

According to a preferred variant of the invention, the tuff layer can be reduced to a few millimeters. Possible thicknesses range from 3mm-4mm to 20mm or more.

According to a preferred production method, a slab of tuff with a thickness S is first cut and placed on a bearing surface.

The natural lime is placed on the tuff layer according to the method as previously elucidated, thus obtaining an intermediate product 1 , which corresponds to the one shown in FIG. 1 or 2 .

When the natural lime layer has been dried, the element obtained is turned over, causing the lime layer 12 to act as a supporting element. Then, another layer 12' of lime is laid on the tuff layer 11. An intermediate product 1b is obtained, as shown in FIG. 3 .

When this second layer 12' of natural lime has been dried, the element obtained is cut perpendicular to the thickness S of the element at the middle part r of the tuff layer 11.

Thus, two building material elements 1 with a thickness of S/2 are obtained.

According to a further variant of the invention, another layer 11' of tuff can be attached to the free face of the lime layer 12, preferably until the lime layer has solidified, so as to form a single body. In this regard, see Figure 4. It should in fact be noted that the element obtained forms a kind of sandwich with lightened lime 12 between two layers of tuff. This variant is generally particularly suitable for the production of curtain walls, partitions and partitions.

According to the invention, the plurality of interlayers comprises several lime layers alternating with tuff layers.

According to a preferred method of production of the curtain wall element, several interlayers are prophylactically produced and subsequently cut perpendicular to the thickness S of the interlayer at the middle portion r of each layer of tuff, as shown in FIG. 3 . Thus, multiple curtain wall elements can be obtained at the same time. Preferably, the interlayer is transported by a conveyor belt so that cutting is performed horizontally, parallel to the direction of travel of the conveyor belt. The support provided by the lime itself allows to obtain a tuff lining provided by the prior art with a thickness of less than 2 cm.

The preferred production method of multiple interlayers can provide superimposition of the upper layer when the lower layer of lime has been partially dried.

Any openings for the passage of water pipes and electrical conduits may already be arranged during the production steps of the building element or curtain wall element according to the invention.

In fact, water pipes and electrical conduits can be embedded in the lime bed, thus greatly simplifying the continuous plant production steps. For example, these solutions cannot be realized with dedicated honeycomb aluminum panels as supports, since there will be no filler material for embedding the ducts.

On the other hand, by combining the inner lining 11 with honeycomb-shaped aluminum support panels and lightened lime, it is also possible to obtain tiles suitable for producing floors and floor surfaces. In this case, the prophylactic insertion of water pipes into the lime layer allows the production of an underfloor heating system.

Due to the nature of tuff, especially when brittle, the tuff-coated element variant is particularly advantageous since it is easy to manipulate to obtain a suitable shape in situ without using special tools. Thus, thanks to the present invention, the excessive fragility of this material has thus been turned into an advantage.

Advantageously, due to the invention:

- construction elements coated with tuff are laid to form almost continuous walls,

-Inlays and finishes can be obtained in these walls,

- Resins, paints or waterproofing agents can be laid over the tuff layer in order to harden it.

These resins and coatings are known per se.

According to the invention, the laying of the elements obtained can advantageously be carried out with additional lime, thus obtaining compositions of the "lime on lime" type, without the use of additional adhesives or additional mechanical components which may include thermal bridges.

Limestone has a surface roughness such that any fixing agent between limestone and lime is also avoided.

After laying, the layer 11 of lining material, whether thin stone or more precisely tuff or ceramic or terracotta tiles, is visible.

Advantageously, according to the invention, the natural lime is laid while already in the solid state, thus limiting the setting time caused by the problem of drying multiple layers of lime. Furthermore, the use of already set lime allows the handling of friable materials that would not be possible without support, such as thin stones or thin slabs of natural tuff.

Furthermore, the lightened lime has a lower specific gravity than that of tuff, and the construction elements obtained according to the invention are lighter than conventional tuff blocks of equal size. Furthermore, it has better insulating properties than simple tuff.

A further advantage offered by the present invention is that, in addition to having excellent physical-mechanical properties, natural lime is far more economical both in terms of the target cost of material and in terms of transport, usually in sacks.

The honeycomb-shaped aluminum panels, which are expensive in themselves, have an unfavorable weight/volume ratio and thus significantly affect shipping costs.

Honeycomb aluminum panels may also be used to help stiffen the building elements described herein when producing building elements of considerable size. For example, an entire wall or a sizable portion thereof. According to a preferred variant of the invention, one or more blocking meshes 13 can be replaced by honeycomb-shaped aluminum panels.

In this case, these honeycomb aluminum panels can be inserted between the layer 11 and the lime 12 or within the thickness of the lime layer 12 .

According to another aspect of the invention, the combination of lightened lime and tuff allows to obtain a favorable mix of thermodynamic characteristics both in terms of insulation and heat capacity. Furthermore, a considerable increase in sound insulation has been noted due to the strong physico-mechanical inhomogeneity of the two materials.

According to a further preferred embodiment of the invention, it is possible to obtain a building module formed from two elements, so that the lime is confined on the inside and only the respective lining layer is visible on the outside.

Above all, this solution is optimal in the production of detachable individual blocks and street walls.

However, elements and features explained in different preferred embodiments can be combined with each other without departing from the scope of protection of the present application.

Claims (11)

1. the Constracture unit for body of wall and wall lining, described Constracture unit comprises at least one lining material (11) and is attached to described inner lining material (11) with the light internal layer of the one forming single main body by drying, it is characterized in that, described internal layer is the natural lime (12) alleviated.

2. element according to claim 1, wherein said lining material (11) comprises the sheet billet of the sandstone of the thickness had between a few tenths of a mm and several millimeters.

3. element according to claim 2, wherein said sheet billet is by tearing acquisition.

4. element according to claim 1, wherein said inner lining material is the tuff (limestone) with the thickness being greater than 3mm-4mm.

5. element according to claim 1, wherein said inner lining material is ceramic tile or similar material.

6., according to element in any one of the preceding claims wherein, wherein fixative is inserted between described inner liner (11) and the described natural stone grieshoch (12) alleviated.

7., according to element in any one of the preceding claims wherein, the wherein said natural stone grieshoch (12) alleviated has the thickness being greater than 1cm.

8. a facade element, described facade element comprises first floor inner lining material (11) and second layer inner lining material (11 '), the natural lime (12) that wherein at least one deck alleviates be inserted into and drying to form interlayer.

9., according to a production method for the Constracture unit described in aforementioned claim, described method comprises at least following steps:

-prepare inner liner (11),

-described inner liner (11) is arranged in the horizontal plane,

-sprawl the natural stone grieshoch (12) alleviated,

The natural stone grieshoch (12) alleviated described in-drying.

10. method according to claim 9, also be included in before sprawling described lkd layer (12), insert the step of at least one reinforcing net (13) of the thickness of described lkd layer (12) and/or on described inner liner (11), prepare the step of fixative.

11., according to the method described in aforementioned claim 9 or 10, also comprise following steps after drying:

The described element that-upset obtains,

-sprawl the other natural stone grieshoch (12 ') alleviated,

-dry described natural stone the grieshoch (12 ') alleviated in addition,

-at respective mid portion (r) place of described inner liner (11), the thickness (S) of the described element obtained perpendicular to described element is cut.