EP4455421A1 - Flat panel and method of manufacturing such a panel - Google Patents

Abstract

The invention relates to a planar panel (2) for forming a wall of a building, which comprises at least one wall body (4) formed from a cured rigid foam and which comprises at least one reinforcement (6) arranged within the cured rigid foam and which has at least one reinforcement means (8) formed entirely or at least in sections from a filament yarn textile.

Description

The invention relates to a planar panel and a method for producing such a panel.

Walls for buildings are known in various forms from the state of the art. These can, for example, be formed by stacking and joining several stones. Walls can also be formed by poured and hardened concrete. In addition, flat wall panels made of wood are known that form a wall and can be joined together.

In order to form a housing wall that complies with the thermal conductivity regulations, an insulating layer must be attached to the wall.

In the case of state-of-the-art walls, in particular wall panels, the provision of a finished wall for a building during assembly involves a large number of steps, which makes assembly time-consuming and costly.

An object of an embodiment of the invention is to propose a planar panel for forming a wall of a housing and a method for producing such a panel, with which a wall of a building can be assembled more time-efficiently.

This object is achieved by a planar panel for forming a wall of a building, which comprises at least one wall body formed from a cured rigid foam and which comprises at least one reinforcement arranged within the cured rigid foam and which has at least one reinforcing means formed entirely or at least in sections from a filament yarn textile.

Because the flat panel is made of a hardened rigid foam and also contains reinforcement within the hardened rigid foam, the load-bearing capacity of the panel and thermal insulation can be achieved in a single component. This means that the assembly for forming a wall of a building can be designed in a time-efficient manner.

By using a hardened rigid foam and reinforcement arranged within the rigid foam, dimensions of up to 3.3 m high, 12 m long and 0.22 m thick can be achieved. By choosing the rigid foam, the panel can have a thermal conductivity group 023.

The panel may comprise a wall panel, ceiling panel, floor panel and/or roof panel.

In this case, a wall is understood to mean a side wall, a floor, a ceiling or a roof element

If the wall includes a ceiling on one floor, this ceiling can simultaneously form a floor on the next floor.

The at least one reinforcement means can in principle be designed in any way desired. Embodiments of the panel are preferred in which at least one of the at least one reinforcement means comprises a fibrous reinforcement element or a rod-shaped reinforcement element and/or in which at least one of the at least one reinforcement means is designed to be flat and comprises a filament yarn textile mat or filament yarn textile grid having a plurality of fibrous reinforcement elements and/or a plurality of rod-shaped reinforcement elements.

If the reinforcement comprises a fibrous reinforcement element or a rod-shaped reinforcement element, this can be easily arranged in sections of the panel which are difficult to access and in which, in particular, no planar reinforcement element can be arranged.

If at least one of the at least one reinforcing means comprises a filament yarn textile mat or a filament yarn textile grid, the reinforcing means can be quickly provided over a large section of the panel, in particular the wall body.

The panel makes it possible to retrofit existing buildings by arranging the panel on existing walls. This can improve the insulation of the wall. However, a wall can also be formed by just one panel. The panel can run in a vertical plane, i.e. enclose an external or internal wall, or run in a horizontal plane, i.e. enclose a floor and/or a ceiling.

In order to ensure the accessibility of an interior space enclosed by the wall and/or to prevent sunlight from entering the space enclosed by the In order to enable the interior space surrounding the wall to be expanded, embodiments of the panel comprise at least one continuous recess in the wall body extending in the width direction of the wall body and at least one frame-like reinforcement unit which is arranged in the wall body adjacent to the recess and which is formed to extend entirely or at least partially around the recess.

By providing recesses extending across the width of the wall body, windows, doors and bridges to other floors can be provided on the panel. By providing a reinforcement unit that is arranged in the wall body adjacent to the recess, the areas of the wall body in which the doors, windows or openings are arranged are strengthened. This improves the force absorption by the wall body.

In a further development of the latter embodiment, it proves to be advantageous if the continuous recess extending in the width direction of the wall body is completely surrounded by the wall body or if the continuous recess extending in the width direction of the wall body is accessible from the outside at least on one side in the longitudinal direction and/or in the vertical direction.

This makes it possible to have embodiments of the panel in which the recess is completely surrounded by the wall body, i.e. the recess is completely framed by the wall body, as well as embodiments in which the recess is accessible from the outside from at least one side. On these sides, the recess is then not limited by the wall body.

If the recess is entirely framed by the wall body, it is advantageous if the wall body, which completely surrounds a continuous recess extending in the width direction, at its narrowest point between the recess and the outer edge has an extension of at least 5 cm, in particular of at least 10 cm.

This makes the pre-assembly of a panel comprising doors and windows easier.

The reinforcement unit can basically be designed in any way. It proves to be advantageous if the reinforcement unit comprises at least one reinforcement means which comprises a fibrous reinforcement element or a rod-shaped reinforcement element and/or if at least one of the at least one reinforcement means is designed to be flat and comprises a filament yarn textile mat or filament yarn textile grid having a plurality of fibrous reinforcement elements and/or a plurality of rod-shaped reinforcement elements.

In such cases, the same or similar elements as those used to form the reinforcement can be used.

As a result, in one embodiment of the panel, it is provided that the filament yarn textile of the reinforcement element and/or the reinforcing element is made of basalt and forms a basalt fiber textile and/or that the cured rigid foam comprises a polyisocyanurate rigid foam (PIR) or a polyurethane foam (PUR).

By choosing PIR or PUR, a material of the thermal conductivity assembly 023 is provided, which in combination with the reinforcement can simultaneously form a wall.

In principle, it is conceivable that the reinforcement comprises only a single reinforcement element. This applies in the same way to the reinforcing unit, which can only comprise a single reinforcement element. The stability and load-bearing capacity of the panel can be further increased if the reinforcement comprises at least two reinforcement elements and the reinforcement comprises at least one spacer, by means of which two of the at least two reinforcement elements are spaced apart from one another without contact, in particular when viewed in the longitudinal direction, vertical direction or width direction of the wall body, and/or that the reinforcing unit comprises at least two reinforcement elements and at least one spacer, by means of which two of the at least two reinforcement elements are spaced apart from one another without contact, in particular when viewed in the longitudinal direction, vertical direction or width direction of the wall body.

In order to improve the accommodation of further elements, for example doors and windows, the panel can comprise at least one frame unit which is fixed flatly against the edge of at least one of the at least one recess in the wall body and which surrounds the recess in a frame-like manner in its entirety or at least in sections.

The frame unit can be made stable and lightweight if the frame unit comprises at least one plate-like frame element comprising a cement-bonded chipboard.

The cement-bonded particle board can comprise a board-shaped wood material formed from wooden rods or a plant material such as hemp or flax. A mineral binder such as cement is also added.

The plate-like frame element can have any thickness. It is advantageous if the frame element is at least 2 cm thick, in particular at least 2.2 cm thick.

In principle, it is conceivable that the panel for forming the wall is provided only with the recesses in the wall body and the reinforcement. In order to simplify final assembly and to reduce the assembly time for the final formation of the wall, embodiments of the panel comprise at least one door element and/or at least one window element that is fixed in the at least one recess.

The door element and/or the window element can then be mounted on the frame unit.

Furthermore, an embodiment of the panel is preferred in which at least one fire barrier element is provided, which forms an outer edge of the panel and is fixed in place against the wall body. The fire barrier element and the wall body can have the same thickness. In this case, the fire barrier element continues the wall body on at least one side. In this case, the fire barrier element can have a thickness of at least 0.20 m, in particular of at least 0.22 m.

By providing the fire barrier element, the pre-assembled panel meets fire protection regulations.

The fire barrier element can comprise a mineral fire barrier. In such a case, the fire barrier element can comprise mineral wool, aerated concrete, perlite or foam glass.

In principle, it is conceivable that the individual components, such as the frame unit, door element, window element and/or fire barrier element, are joined after the hard foam forming the wall body has hardened. However, it is also conceivable that the fire barrier element in particular is joined to the fire body by arranging the fluid hard foam on the fire barrier element and allowing it to harden in such an arrangement.

The same applies to frame elements, door elements and window elements.

1. a. Zur Verfügung stellen und Anordnen einer mehrere Schalungselemente umfassende Verschalung;
2. b. Anordnen der Bewehrung innerhalb der Verschalung;
3. c. Schließen der Verschalung
4. d. Eingeben oder Einfüllen des den Wandkörper bildenden Hartschaums in die Verschalung;
5. e. Aushärten des Systems aus Hartschaum und Bewehrung.

Furthermore, the object is achieved by a method for producing a panel with at least one of the aforementioned features, comprising the steps:

1. a. Providing and arranging a formwork comprising several formwork elements;
2. b. Arranging the reinforcement within the formwork;
3. c. Closing the formwork
4. d. Inserting or filling the rigid foam forming the wall body into the formwork;
5. e. Curing of the rigid foam and reinforcement system.

1. a. Anordnen von Ausnehmungs-Schalungselementen zum Bilden der mindestens einen Ausnehmung; und/oder
2. b. Anordnen von Verstärkungsmitteln der Verstärkungseinheit in Gänze oder zumindest abschnittsweise um die Ausnehmungs-Schalungselementen herum.

Step a. means that the essential parts of the formwork elements are joined together and leave access for arranging the reinforcement within the formwork. This is then closed in step c. in such a way that the rigid foam forming the wall body can be inserted or filled into the formwork. Further procedural steps may be provided which

1. a. Arranging recess formwork elements to form the at least one recess; and/or
2. b. Arranging reinforcing means of the reinforcing unit in its entirety or at least in sections around the recess formwork elements.

If recesses are to be provided in the wall body, these can be ensured by appropriately designing the formwork elements to ensure a material-free space in the wall body.

In addition, the reinforcing means of the reinforcement unit can be arranged around these recess formwork elements.

1. a. Anordnen mindestens eines Brandriegelelements in der Verschalung zumindest vor dem Eingeben oder Einfüllen des Hartschaums in die Verschalung;
2. b. Anordnen mindestens eines Zargenelements der Zargeneinheit in der mindestens einen Ausnehmung des Wandkörpers nach dem Aushärten des Hartschaums; und/oder
3. c. Anordnen mindestens eines Türelements und/oder mindestens eines Fensterelements in der mindestens einen Ausnehmung des Wandkörpers nach dem Anordnen des Zargenelements der Zargeneinheit in der Ausnehmung des Wandkörpers.

Finally, the following further procedural steps may be provided:

1. a. Arranging at least one fire barrier element in the formwork at least before inserting or filling the rigid foam into the formwork;
2. b. Arranging at least one frame element of the frame unit in the at least one recess of the wall body after the hard foam has hardened; and/or
3. c. Arranging at least one door element and/or at least one window element in the at least one recess of the wall body after arranging the frame element of the frame unit in the recess of the wall body.

Further features, details and advantages of the invention emerge from the appended patent claims, from the drawings and the following description of a preferred embodiment of the panel and the method.

Figur 1

Eine perspektivische Vorderansicht mit explosionsartig dargestellten Komponenten eines erfindungsgemäßen Panels;

Figur 2

Ein schematisches Ablaufdiagramm einer Ausführungsform des erfindungsgemäßen Verfahrens.

In the drawing shows:

Figure 1

A perspective front view with exploded components of a panel according to the invention;

Figure 2

A schematic flow diagram of an embodiment of the method according to the invention.

Figure 1 shows a panel, generally designated with the reference number 2, which represents a wall of a building (in Figure 1 not explicitly shown).

The planar panel 2 comprises a wall body 4, which is made of a hardened rigid foam. A reinforcement 6 is arranged in the wall body 4, which in the Figure 1 shown embodiment comprises several reinforcement means 8. The reinforcement means 8 is formed entirely from a filament yarn textile, in particular a basalt fiber textile.

In the Figure 1 In the embodiment shown, the reinforcement means 8 of the reinforcement 6 comprises a plurality of fibrous reinforcement elements which form a filament yarn textile mat or a filament yarn textile grid.

In the Figure 1 In the embodiment shown, the panel 2 comprises a fire barrier element 10 which forms an outer edge of the panel 2 and is fixed flatly to the wall body 4. The fire barrier element 10 comprises a mineral fire barrier element 10.

Figure 1 shows an embodiment of the planar panel 2, with two recesses 12 which are formed to extend continuously in the width direction of the wall body 4 and are completely surrounded by the wall body 4.

At the recesses 12, the panel 2 comprises a reinforcement unit 14, which comprises at least one reinforcement means 16, which is formed by fibrous reinforcement elements and/or rod-shaped reinforcement elements. The reinforcement elements also comprise a filament yarn textile. The reinforcement unit 14 completely surrounds the recess 12 in its circumferential direction.

In addition, a frame unit 18 is arranged in each of the recesses 12 of the panel 2, which comprises at least one plate-shaped frame element 20.

In the Figure 1 In the embodiment shown, a door element 22 is arranged in one of the two recesses 12 and a window element 24 is arranged in the other recess 12.

Figure 2 shows a schematic flow diagram. Using the representation according to Figure 1 the procedure is described below:
In a first step 100, several formwork elements are provided and arranged to form a formwork.

In a subsequent step 101, the reinforcement 6 is arranged within the formwork.

In a subsequent step 102, the formwork is closed.

Thereafter, in a step 103, the rigid foam forming the wall body 4 is inserted or filled into the formwork.

In a final step 104, the system of rigid foam and reinforcement 6 is cured.

The features of the invention disclosed in the above description, in the claims and in the drawings can be essential both individually and in any combination in the realization of the invention in its various embodiments within the scope of protection of the following claims.

list of reference symbols

2

panel

4

wall body

6

reinforcement

8

reinforcement

10

fire barrier element

12

recess

14

amplification unit

16

reinforcing agents

18

frame unit

20

frame element

22

door element

24

window element

100- 104

procedural steps

Claims (15)

Flat panel (2) for forming a wall of a building, which comprises at least one wall body (4) which is formed from a cured rigid foam and which comprises at least one reinforcement (6) which is arranged within the cured rigid foam and which has at least one reinforcement means (8) which is formed entirely or at least in sections from a filament yarn textile. Panel (2) according to claim 1, characterized in that at least one of the at least one reinforcement means (8) comprises a fibrous reinforcement element or a rod-shaped reinforcement element and/or that at least one of the at least one reinforcement means (8) is designed to be planar and comprises a filament yarn textile mat or filament yarn textile grid having a plurality of fibrous reinforcement elements and/or a plurality of rod-shaped reinforcement elements. Panel (2) according to claim 1 or 2, characterized by at least one continuous recess (12) in the wall body (4) extending in the width direction of the wall body (4) and by at least one frame-like reinforcement unit (14) which is arranged in the wall body (4) adjacent to the recess (12) and which is designed to extend entirely or at least partially around the recess (12). Panel (2) according to claim 3, characterized in that the continuous recess (12) extending in the width direction of the wall body (4) is completely surrounded by the wall body (4) or that the continuous recess (12) extending in the width direction of the wall body (4) continuous recess (12) is accessible from the outside on at least one side in the longitudinal direction and/or in the vertical direction of the wall body. Panel (2) according to claim 4, characterized in that the wall body (4), which completely surrounds the continuous recess (12) extending in the width direction, has an extension of at least 5 cm, in particular of at least 10 cm, at its narrowest point between the recess (12) and the outer edge. Panel (2) according to one of claims 3 to 5, characterized in that the reinforcing unit (14) comprises at least one reinforcing means (16) which comprises a fibrous reinforcing element or a rod-shaped reinforcing element and/or that at least one of the at least one reinforcing means (16) is designed to be planar and comprises a filament yarn textile mat or filament yarn textile grid having a plurality of fibrous reinforcing elements and/or a plurality of rod-shaped reinforcing elements. Panel (2) according to one of the preceding claims, characterized in that the filament yarn textile of the reinforcement element and/or the reinforcing element is made of basalt and forms a basalt fiber textile and/or that the cured rigid foam comprises a polyisocyanurate rigid foam (PIR) or a polyurethane foam (PUR). Panel (2) according to one of the preceding claims, characterized in that the reinforcement (6) comprises at least two reinforcement means (8) and the reinforcement (6) comprises at least one spacer, through which two of the at least two reinforcement means (8), in particular in the longitudinal direction, vertical direction or viewed in the width direction of the wall body (4), are spaced apart from one another without contact and/or that the reinforcing unit (14) comprises at least two reinforcing means (16) and at least one spacer, by means of which two of the at least two reinforcing means (16), viewed in particular in the longitudinal direction, vertical direction or width direction of the wall body (4), are spaced apart from one another without contact. Panel (2) according to one of claims 3 to 8, characterized by at least one frame unit (18) which is fixed in a planar manner against the edge of at least one of the at least one recess (12) in the wall body (4) and which surrounds the recess (12) in the manner of a frame in its entirety or at least in sections. Panel (2) according to claim 9, characterized in that the frame unit (18) comprises at least one plate-like frame element (20) which comprises a cement-bonded chipboard. Panel (2) according to one of claims 3 to 10, characterized by at least one door element (22) and/or by at least one window element (24) which is fixed in the at least one recess (12). Panel (2) according to one of the preceding claims, characterized by at least one fire barrier element (10) which forms an outer edge of the panel (2) and which is fixed in a planar manner to the wall body (4). Method for producing a panel (2) according to one of claims 1 to 12, comprising the steps: a. Providing and arranging a formwork comprising several formwork elements; b. Arranging the reinforcement (6) within the formwork; c. Closing the formwork d. Inserting or filling the rigid foam forming the wall body (4) into the formwork; e. Curing of the rigid foam and reinforcement system (6). Method according to claim 13, characterized by the steps: a. Arranging recess formwork elements to form the at least one recess (12); and/or b. Arranging reinforcing means (16) of the reinforcing unit (14) entirely or at least in sections around the recess formwork elements. Method according to claim 13 or 14, characterized by the step: a. Arranging at least one fire barrier element (10) in the formwork at least before inserting or filling the rigid foam into the formwork; b. Arranging at least one frame element (20) of the frame unit (18) in the at least one recess (12) of the wall body (4) after the hard foam has hardened; and/or c. Arranging at least one door element (22) and/or at least one window element (24) in the at least one recess (12) of the wall body (4) after arranging the frame element (20) of the frame unit (18) in the recess (12) of the wall body (4).

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