METHOD FOR THE PRODUCTION OF THERMAL BARRIER BLOCKS

Abstract

The invention relates to perforated building blocks (1) which are filled with thermal insulation material (2), as well as a method and a system for the production thereof.

Claims

1-26. (canceled)

27. A perforated building block, comprising: at least one opening of the perforated building block filled with thermal insulation material, the thermal insulation material being introduced in a moist, free-flowing state into the at least one opening; and at least one side of said at least one opening provided with a covering layer formed from a cured setting material.

28. The perforated building block according to claim 27, wherein the thermal insulation material comprises closed hollow microspheres or closed-cell perlite in the form of hollow microspheres.

29. The perforated building block according to claim 27, wherein the thermal insulation material comprises heat-insulating particles and a binder.

30. The perforated building block according to claim 29, wherein: the heat-insulating particles are enclosed in the set binder so that the thermal insulation material in the perforated building block is not free-flowing; the moist thermal insulation material being compressed in the perforated building block to enclose the heat-insulating particles in the binder; the moist thermal insulation material being such that without compressing the moist thermal insulation material, the heat-insulating particles are not enclosed in the binder during drying and remain free-flowing.

31. The perforated building block according to claim 30, wherein the material of the covering layer is introduced into free space in the opening of the perforated building block resulting from compressing the moist thermal insulation material.

32. The perforated building block according to claim 27, wherein the covering layer is formed from a mineral material which is cured after contact with liquid, the mineral material being applied in a free-flowing state and being set by subsequent application of liquid.

33. The perforated building block according to claim 27, wherein the covering layer and the thermal insulation material are formed from formulations which differ in at least one property selected from the group of properties comprising: presence of heat-insulating particles; proportion of heat-insulating particles; water content; presence of a binder; material of the binder; and proportion of the binder.

34. A method for producing a perforated building block which is filled with a thermal insulation material, comprising the steps: filling the thermal insulation material in at least one opening of the perforated building block; and providing said opening on at least one side thereof with a covering layer by applying a setting material in a free-flowing state and subsequently applying a liquid to set said setting material.

35. The method according to claim 34, wherein the thermal insulation material being introduced into the openings in the form of a free-flowing material.

36. The method according to claim 34, wherein the thermal insulation material is introduced into the openings in a moist state.

37. The method according to claim 34, wherein the thermal insulation material is compressed after filling in the openings.

38. The method according to claim 34, wherein the setting material is applied in a dry state to the thermal insulation material and liquid is subsequently applied to the setting material so that it cures.

39. A system for the production of perforated building blocks which are filled with thermal insulation material, comprising: a transport device on which at least one row of perforated building blocks can be placed next to one another, the transport device continuously transporting this row through the system; an introduction device with which free-flowing thermal insulation material is introduced into openings of the perforated building blocks while they are continuously transported by the transport device; and a device for applying setting material which device applies setting material to the thermal insulation material present in the openings of the perforated building blocks while they are continuously transported by the transport device.

40. The system according to claim 39, wherein the thermal insulation material is moistened before being introduced by the introduction device, the thermal insulation material comprising heat-insulating particles and binders.

41. The system according to claim 39, wherein a stripping element which is attached downstream of the introduction device and upstream of the device for applying the setting material strips excess thermal insulation material from the top the perforated building blocks.

42. The system according to claim 39, wherein a compacting device is attached downstream of the introduction device or downstream of a stripping element and upstream of the device for applying setting material, which compacting device compresses the thermal insulation material in the openings of the perforated building blocks.

43. The system according to claim 39, wherein downstream of the device for applying setting material there is a stripping element which strips excess setting material from the top of the perforated building blocks.

44. The system according to claim 39, wherein downstream of the device for applying setting material there is a device for applying liquid to the setting material.

45. The system according to claim 39, wherein the system comprises a turning device following the transport device and the system comprises a further transport device downstream of the turning device and a further device for applying setting material which applies setting material from the second side of the perforated building blocks to the thermal insulation material present in the openings of the perforated building blocks.

46. The system according to claim 45, wherein the system comprises at least these devices following the turning device: a first compacting device which compresses the thermal insulation material in the openings of the perforated building blocks; a device for applying setting material; a stripper element which strips excess material from the top of the perforated building blocks; a second compacting device which presses setting material into the openings of the perforated building blocks; and a device for applying liquid to the setting material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Preferred embodiment variants according to the invention are illustrated by way of example with reference to the drawings and are in no case limiting:

[0069] FIG. 1: Shows a first variant of an exemplary perforated building block according to the invention in a sectional view from the side.

[0070] FIG. 2: Shows a second variant of an exemplary perforated building block according to the invention in a sectional view from the side.

[0071] FIG. 3: Shows schematically the preferred manufacturing method according to the invention of the covering layer on the perforated building block filled with insulation material.

[0072] FIG. 4: Shows schematically the preferred manufacturing method according to the invention of the covering layer on the second side of a perforated building block filled with insulation material.

[0073] FIG. 5: Shows schematically the preferred manufacturing method according to the invention of a thermal insulation brick according to the invention with the preferred system according to the invention in a side view.

[0074] FIG. 6: Shows schematically the preferred manufacturing method according to the invention of a thermal insulation brick according to the invention with the preferred system according to the invention in a view from above.

DETAILED DESCRIPTION

[0075] FIG. 1 shows a perforated building block 1 according to the invention in the form of a vertically perforated brick which is filled with insulation material 2, the openings of the perforated building block 1 being closed on one side with a covering layer 3. During transport and handling, the covering layer 3 preferably points downwards, so that no insulation material 2 can get down out of the perforated building block 1.

[0076] FIG. 2 shows a perforated building block 1 according to the invention in the form of a vertically perforated brick which is filled with insulation material 2, the openings of the perforated building block 1 being closed on both sides with a covering layer 3.

[0077] As can be seen in FIGS. 1 and 2, the covering layers 3 are preferably present within the openings of the perforated building block 1 so that the material of the covering layers 3 does not protrude above the bottom or top of the perforated building block 1.

[0078] FIG. 3 illustrates the preferred manufacturing method of the covering layers 3 and the thermal insulation brick according to the invention. The filling and sealing process is preferably carried out continuously, the perforated building blocks 1 being moved through the device in a row (abutting one another) by a transport device 4, in particular a conveyor belt. In the first step, the openings of the perforated building block 1 are filled with free-flowing material 5 which forms the insulation material 2 (this step is shown in FIG. 5).

[0079] As can be seen on the far right in FIG. 3, excess free-flowing material 5 which is located on the outside of the perforated building block 1, can be stripped off with a first stripping element 6, for example a strip, a rubber lip or a brush, the excess free-flowing material 5 is pushed into possibly incompletely filled openings, or is pushed sideways from the perforated building blocks 1.

[0080] After the first step, the free-flowing material 5 can be compressed in the openings, preferably by rolling a first roller 7 made of elastic material, preferably rubber, on the top of the perforated building blocks 1.

[0081] In the second step, a setting material 8, preferably in the dry state, is applied to the top of the perforated building blocks 1.

[0082] After the second step, excess setting material 8 can be removed from the top of the perforated building blocks 1 with a second stripping element 9.

[0083] After the second step, the setting material 8 can be compressed in the openings, for example by a second roller 10 made of elastic material, preferably rubber, rolling on the top of the perforated building blocks 1.

[0084] If the setting material 8 has been applied in the dry state, as is preferred, this is sprayed with liquid 11 in the third step, the setting material 8 cures after contact with the liquid 11 to form the covering layer 3. The setting material is preferably cement which is sprayed with water. The application of the setting material 8 in the dry state has the advantage that excess dry setting material 8 can simply be wiped away without it adhering to and curing on surfaces. In addition, the device for applying the setting material 8 is not contaminated and/or blocked by curing material which would require regular cleaning. The setting material 8 can in particular be sprayed on or sprinkled on. It is also possible to have a container which is open at the bottom and is present in the width of the bricks and is at least approximately close thereto and is filled with the setting material 8, as illustrated in FIG. 4.

[0085] The stripping and/or pressing of the free-flowing material 5 and/or the setting material 8 means that the top of the perforated building blocks 1 remains at least largely free of material 5, 8 which is advantageous when installing the perforated building blocks 1.

[0086] Subsequently, the perforated building blocks 1 can be turned (not shown) and, as shown in FIG. 4, the already sealed side can be moved downward through a further sealing system. The free-flowing material 5 can first be compressed from the second side, for example again with an elastic roller or third roller 13. Then, a setting material 8, preferably in the dry state, is applied to the top of the second side of the perforated building blocks 1.

[0087] After this step, excess setting material 8 can be removed from the top of the perforated building blocks 1 with a third stripping element 14.

[0088] After this step, the setting material 8 can be compacted in the openings, for example by a fourth roller 15 made of elastic material, preferably rubber, rolling on the top of the perforated building blocks 1.

[0089] If the setting material 8 has been applied in the dry state, it is sprayed with liquid 11 in the next step, and the setting material 8 cures after contact with the liquid 11 to form the covering layer 3. The setting material 8 is preferably cement which is sprayed with water.

[0090] FIG. 5 shows the system according to the invention with the introduction device 16 and material supply 17 of the free-flowing material 5. The perforated building blocks 1 are placed on the right of the introduction device 16 on the transport device 4, the introduction device 16 having a width such that all openings of the perforated building blocks 1 located below can be filled with free-flowing material 5. The introduction device 16 is supplied with the free-flowing material 5 via a material feed 17, for example from the outlet end of a mixer which mixes the free-flowing material 5 from several components and/or treats the free-flowing material 5 with moisture, preferably with water. The mixer is preferably a continuous flow mixer which can continuously supply the pouring device with free-flowing material 5. In any case, a continuous mixer is more suitable for the present process in question than a batch mixer.

[0091] Alternatively, the free-flowing material 5 can come directly from a storage container and can be transported into the introduction device 16 without further processing.

[0092] As shown in FIGS. 5 and 6, the introduction device 16 preferably comprises a container which is open at the bottom towards the perforated building blocks 1 and which is stationary just above the perforated building blocks 1 passing therethrough, so that free-flowing material 5 from the container arrives into the openings of the perforated building blocks 1, wherein movable means for regular distribution of the free-flowing material 5 can be provided in the container. Because the container is just above the perforated building blocks 1 and corresponds to the width thereof, only a small part of the free-flowing material 5 reaches the conveyor device laterally and through the gap between the front end of the container and the perforated building blocks 1. In this case, a plurality of perforated building blocks 1 can also be placed parallel to one another on the transport device 4 so that they are simultaneously supplied with free-flowing material 5, as illustrated in FIG. 6.

[0093] Material that comes laterally from the introduction device 16 onto the transport device 4 and/or is stripped from the top of the perforated building blocks 1 by the stripping element 5 is preferably fed back into the container by a return transport device 18 and thus directly reused, preferably without preparation, for filling the perforated building blocks 1. The return transport can be realised, for example, by suction or a return conveyor belt.

[0094] The same could of course also be implemented for the setting material 8, so that the stripped setting material 8 is fed back to the application device therefor.

[0095] As illustrated in FIGS. 5 and 6, the entire filling and sealing process takes place continuously, the perforated building blocks 1 being conveyed by the transport device 4 at a constant speed and without intermediate stops. It is particularly advantageous that no handling devices or work stations need to be moved in the transport direction with the perforated building blocks 1, which results in a simple and energy-saving plant construction, since constant acceleration and braking of transport devices or work stations can be omitted.

[0096] The present filling system and/or the present sealing system can be connected or integrated into a production system of perforated building blocks 1, in particular hollow perforated bricks, in that the production line of the production system runs through the present system as a transport device 4, or the transport device 4 is connected to the production line. The production line preferably has a switch element so that a partial quantity of the perforated building blocks 1 produced can be filled by the system according to the invention and a different partial quantity can be produced as unfilled perforated building blocks 1.

[0097] However, the present system can also be used as a stand-alone or offline system which preferably has loading and unloading robots which are preferably used to place perforated building blocks 1 in front of the introduction device 16 on the transport device 4 and to lift from the transport device 4 after the last sealing process. The perforated building blocks 1 can be lifted off the production line of a production system and, after filling and sealing, can also be placed there again. The unfilled perforated building blocks 1 can also be delivered on pallets, whereby it is always conceivable to simultaneously lift an entire layer of perforated building blocks 1 from the pallet and place them on the transport device 4. After the last sealing has taken place, the heat-insulating bricks which are produced can advantageously be removed from the transport device 4 and immediately placed on pallets and transported away for storage or to the place of use. This is possible since a fast-curing setting material 8 is preferably used which obtains the necessary strength particularly quickly due to the rather small layer thickness of the covering layer 3.

[0098] Since the free-flowing material 5 is introduced in a dry to moist state and in any case not as a liquid, the heat insulating bricks do not require any or hardly any time to dry out sufficiently, so that these could be installed immediately after production. Autoclaving or other heating of the manufactured thermal insulation bricks can be avoided in any case.

[0099] Since the filling and sealing of the perforated building blocks 1 can take place at room temperature, no cooling of the manufactured thermal insulation bricks is necessary.