HABITATION BLOCK AND METHOD FOR PRODUCING THERMAL INSULATION

Abstract

A habitation block including habitation levels that are arranged on top of each other, wherein at least one of the habitation levels includes adjacent habitation units including an outer shell formed from a cuboid container that includes a placement surface, a cover, up to two lateral walls and up to two face walls, a cuboid interior space which has an edge length of at least 2 m, a walkable base with step soundproofing, a room ceiling, and room walls, wherein the room walls are dry walls with an intermediary space formed between the cover and the up to four lateral walls and between the room ceiling and the room walls, and a monolithic thermal insulation in the intermediary space, wherein the thermal insulation fills the intermediary space completely and is glued together with the room ceiling and with the room walls.

Claims

1. A habitation block, comprising: habitation levels that are arranged on top of each other, wherein at least one of the habitation levels includes adjacent habitation units including an outer shell formed from a cuboid container that includes a placement surface, a cover, up to two lateral walls and up to two face walls, a cuboid interior space which has an edge length of at least 2 m respectively, a walkable base with step soundproofing, a room ceiling, and up to four room walls, wherein the up to four room walls are dry walls with an intermediary space formed between the cover and the up to four lateral walls and between the room ceiling and the up to four room walls, and a monolithic thermal insulation in the intermediary space, wherein the thermal insulation fills the intermediary space completely and is glued together with the room ceiling and with the up to four room walls so that the thermal insulation forms a substructure that stabilizes the dry walls.

2. The habitation block according to claim 1, wherein the thermal insulation is made from a polyurethane hard foam with closed pores.

3. The habitation block according to claim 1, wherein the room walls or the room ceiling include at least one layer made from an elastic material.

4. The habitation block according to claim 1, wherein the up to 4 room walls, the base and the room ceiling include a minerally bonded cover layer on an inside that is oriented towards the interior space, or wherein the up to 4 room walls, the base and the room ceiling are made from a wood material.

5. The habitation block according to claim 4, wherein the base includes a dry screed with an area weight of at least 50 kg/m.sup.2.

6. The habitation block according to claim 1, wherein the base includes a floor heater.

7. The habitation block according to claim 1, wherein the shell is a sea container.

8. The habitation block according to claim 7, wherein the shell has a length of 12 m and a height of 2.9 m.

9. The habitation block according to claim 1, wherein the shell and the up to 4 room walls are interrupted so that the interior space is connected with an outer environment of the shell.

10. The habitation block according to claim 9, wherein the interior spaces of adjacent habitation units are connected through interrupted shells and the interrupted room walls.

11. The habitation block according to claim 1, wherein the outer shell includes a pass through opening at a face side wherein the pass through opening extends parallel to the face side and the interior space is separated by a divider wall from the pass through opening.

12. The habitation block according to claim 1, wherein pass through openings of the adjacent habitation units connect with each other and form a walkway.

13. The habitation block according to claim 12, wherein walk ways of the habitation levels are connected with each other by stairs or elevators.

14. A method for producing a thermal insulation between a room wall of a cuboid interior space and an exterior wall that is parallel to the room wall, wherein the interior space has an edge length of at least 2 m respectively and the exterior wall is configured at a cuboid container which envelopes the interior space, the method comprising the steps: initially attaching an interior surface of the room wall that is oriented towards the interior space at a core and positioning the interior surface together with the core parallel to the exterior wall before injecting a foam, supporting an exterior surface of the exterior wall that is oriented towards an exterior ambient of the container by a support device perpendicular to the interior surface, thereafter injecting a curing foam between the room all and the exterior wall, and after curing the foam removing the core from the interior surface and removing the support device from the exterior surface, wherein the room wall is a dry wall which is attached at the core by a vacuum, and wherein the thermal insulation replaces a substructure that stabilizes the dry wall.

15. The method according to claim 14, wherein the foam is injected in layers that are arranged vertically on top of each other.

16. The method according to claim 14, wherein the foam is simultaneously injected between a second room wall (14) and a second exterior wall, and wherein the room wall is arranged in the interior space opposite to the room wall and the exterior wall is configured at the container opposite to the second exterior wall.

17. The method according to claim 14, further comprising the step: subsequently injecting the foam between a room ceiling that terminates the room in upward direction and a cover that terminates the container in the upward direction.

18. The method according to claim 14, wherein injecting the foam between the room wall and the exterior wall is documented by a camera.

19. A method for producing a habitation unit for a habitation block according to claim 1, wherein the thermal insulation is produced between a room wall of a cuboid interior space and an exterior wall that is parallel to the room wall, wherein the interior space has an edge length of at least 2 m respectively and the exterior wall is configured at a cuboid container which envelopes the interior space, the method comprising the steps: initially attaching an interior surface of the room wall that is oriented towards the interior space at a core and positioning the interior surface together with the core parallel to the exterior wall before injecting a foam, supporting an exterior surface of the exterior wall that is oriented towards an exterior ambient of the container by a support device perpendicular to the interior surface, thereafter injecting a curing foam between the room wall and the exterior wall, and after curing the foam removing the corefrom the interior surface and removing the support device from the exterior surface, wherein the room wall is a dry wall which is attached at the core by a vacuum, and wherein the thermal insulation replaces a substructure that stabilizes the dry wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The invention is subsequently described based on an embodiment with reference to a drawing FIGURE.

[0043] The drawing FIGURE illustrates a habitation block according to the invention.

[0044] The first habitation unit 1 according to the invention illustrated in the drawing figure includes an outer shell 2 made from a 40 HC sea container and a cuboid interior space 3 and an interior space 4 with thermal insulation 5 between the shell 2 and the interior space 3.

[0045] The outer shell 2 includes a horizontally extending placement surface 6 and there above and parallel to the placement surface 6, a cover 7, two side walls 8 and two face walls 9, 10. The side walls 8 are interrupted by two door openings 11 and the front face wall 9 is provided as a fall safety. The interior space 3 includes a walkable floor 12 and there above in parallel to the floor 12 a room ceiling 13 and four vertical room walls 14, 15.

[0046] The room walls 14, 15, the floor 12 and the room ceiling 13 respectively include gypsum fiber plates as a minerally bonded cover layer which is defined towards the thermal insulation 5 by a pressure resistant vapor barrier 16 made from aluminum.

[0047] In order to produce the habitation unit 1 the room walls 14, 15 and the room ceiling 13 are attached by vacuum at a non-illustrated core and inserted with the core into the previously emptied shell 2. The shell 2 is clamped from an outside in a support device that is not illustrated either.

[0048] Then a polyurethane hard foam is injected for the thermal insulation 5 with a pressure above 200 bar by two spraying devices that are not illustrated wherein the injecting is initially performed simultaneously between two room walls 14, 15 and the shell 2 in layers that extend vertically above one another and subsequently the insulation is injected in adjacent layers between the room ceiling 13 and the shell 2,

[0049] After curing the thermal insulation 5 the vacuum is removed, the core is separated from the from the room walls 14, 15 and room ceiling 13. The room walls 14, 15 are moved towards each other, the core is removed from the interior space 3 and the clamping in the support device is disengaged.

[0050] After installation of the floor 12 with a plate shaped prefabricated thermal insulation, walking noise insulation and floor heating 18 the habitation unit is ready for interior finishing.

[0051] The interior space 4 is phoned with a monolithic thermal insulation 5 made from polyurethane hard foam between the cover 7 and the room ceiling 13 and between the side walls 8 and the rear face wall 10 and the room walls 14 and is thus completely filled without any gaps. The thermal insulation 5 is glued with its entire surface with the room ceiling 13 and with the room walls 14 as well as with the shell 2 and furthermore envelops the front room wall 15 of the inner space 3 wherein the front room wall 15 simultaneously forms a divider wall 19 to a pass through 20 between the two door openings 11 that is integrated into the habitation unit 1.

[0052] The interior space 3 of the habitation unit 1 according to the invention has a useable habitation surface of 9.5 m2.2 m=20.9 m.sup.2, with a room height 21 of 2.4 m. The habitation unit 1 according to the invention has excellent sound insulation properties, complies with the passive house energy standard and is recyclable to a large extent. Several habitation units 1 can be arranged adjacent to each other so that the door openings 11 of adjacent habitation units match and the pass through alleys 20 form a common covered walking alley.

[0053] A second, third, fourth and fifth habitation unit that is produced according to the invention is not illustrated but substantially corresponds to the first habitation unit 1. The second habitation unit does not have a pass through for a walking alley but a useable habitation surface of 12 meters2.2 meters=26.4 m.sup.2. The third habitation unit is provided for installation in a stack of habitation units produced according to the invention and has no thermal insulation between the placement surface and the floor and between the cover and the room ceiling.

[0054] The fourth and fifth habitation unit do not have a vapor barrier but an elastic layer made from mineral wool that is connected with the gypsum fiber plate and sound decouples the interior space from the shell and thus from the environment or adjacent habitation units. In the fourth habitation unit the polyurethane hard foam is directly adjacent to the mineral wool, the fifth habitation unit includes a prefabricated double gypsum fiber plate with an intermediary layer made from the mineral wool which simplifies handling.

REFERENCE NUMERALS AND DESIGNATIONS

[0055] 1 habitation unit

[0056] 2 outer shell

[0057] 3 interior space

[0058] 4 intermediary space

[0059] 5 thermal insulation

[0060] 6 placement surface

[0061] 7 cover

[0062] 8 wall

[0063] 9 front face wall

[0064] 10 rear face wall

[0065] 11 door opening

[0066] 12 walkable floor

[0067] 13 room ceiling

[0068] 14 room wall

[0069] 15 front room wall

[0070] 16 vapor barrier

[0071] 17 walking sound insulation

[0072] 18 floor heating

[0073] 19 divider wall

[0074] 20 pass through opening

[0075] 21 room height