Building Wall

Abstract

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).

Claims

1. Building wall, in particular floor wall, roof wall or side wall, with a base frame comprising a plurality of braces, wherein the base frame forms an intermediate space between the braces, wherein the intermediate space is filled by a foamed filling material.

2. Building wall according to claim 1, characterised in that the base frame is dimensioned in such a way that a required load-bearing capacity of the building wall is not provided by the base frame.

3. Building wall according to claim 1, characterised in that the filled intermediate space, in particular next to the braces, is delimited by a, in particular textile, enveloping form.

4. Building wall according to claim 3, characterized in that the enveloping form comprises an outer shell delimiting the intermediate space on a wall outer side, and that the enveloping form comprises an inner shell delimiting the intermediate space on a wall inner side.

5. Building wall according to claim 4, characterised in that the outer shell and the inner shell are connected to one another by at least one connecting thread, in particular a plurality of connecting threads, in particular wherein the connecting thread bridges the intermediate space.

6. (canceled)

7. (canceled)

8. Building wall according to claim 1, characterised in that the filling material is placed under an internal pressure of at least 1.2 bar after curing and/or during foaming and curing, and/or that the filling material exerts a pressure load of at least 1.2 bar on the inner shell and/or on the outer shell.

9. (canceled)

10. Building wall according to claim 1, characterised in, that the enveloping form is attached to a brace of the base frame, in particular that the outer shell is attached to an outer side of a brace of the base frame and/or that the inner shell is attached to an inner side of a brace of the base frame.

11. Building wall according to claim 1, characterised in that 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 particular in that two adjacent intermediate spaces within a wall are in each case delimited by two separate enveloping forms.

12. Building wall according to claim 1, characterised in that a common brace is arranged between the two adjacent intermediate spaces, the two separate outer shells and/or inner shells being attached to the common brace.

13. Building wall according to claim 1, characterized in that the enveloping form has a first shell which is designed to delimit a plurality of intermediate spaces, and in that the enveloping form has at least two separate second shells, which are each designed to delimit an intermediate space, the two separate second shells being connected to the first shell via connecting threads, a passage being provided between the two second shells for a brace to pass through.

14. Building wall according to claim 1, characterized in that the enveloping form has a first shell which is designed to delimit a plurality of intermediate spaces, and in that the enveloping form has a second shell which is designed to delimit a plurality of intermediate spaces, the second shell being connected to the first shell via the connecting threads, an insertion channel for passing a brace being provided between the first shell, the second shell and the connecting threads.

15. Building wall according to claim 1, characterised in that the building wall has a plurality of intermediate spaces between one another, each of which is separated from the other by a brace.

16. Building wall according to claim 1, characterised in that the wall is a side wall or a roof wall and in that the base frame has at least three horizontal braces arranged one above the other so that a plurality of intermediate spaces arranged one above the other are formed.

17. Building wall according to claim 1, characterised in that the wall is a floor wall which is arranged on a ground, the intermediate space being limited on the floor side at least indirectly by the ground.

18. (canceled)

19. (canceled)

20. A building comprising a plurality of walls according to claim 1.

21. Method of manufacturing a wall according to claim 1, 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, the filling material foaming up after filling.

22. Method according to claim 21, wherein the enveloping form is prefabricated and/or wherein 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.

23. Method according to claim 21, wherein the enveloping form is passed at least partially through the intermediate space, and wherein an outer shell of the enveloping form is fastened to a brace on the outside of the wall, and in that an inner shell of the enveloping form is fastened to the brace on the inside of the wall.

24. Method according to claim 21, characterised in that the filling material has, when filled, a viscosity of at most 1000 mPa*s, in particular and in that the inner shell and the outer shell lie sealingly against the base frame when filled.

25. (canceled)

26. Method of manufacturing a wall according to claim 21, wherein prior to filling the intermediate space with filler material, a target density of the filler material is determined; based on the target density and based on the volume of the intermediate space, an amount of filler material is determined; subsequently, the filling of the intermediate space with the determined amount of filling material is performed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The invention is explained in more detail below with reference to the figures; herein shows:

[0052] FIG. 1 a base frame of a side wall according to the invention;

[0053] FIG. 2A an enveloping form of a wall according to the invention in one embodiment in a first representation;

[0054] FIG. 2B an enveloping form of a wall according to the invention in one embodiment in a second representation;

[0055] FIG. 2C an enveloping form of a wall according to the invention in one embodiment in a third representation;

[0056] FIG. 3A the first process step for the manufacturing of a side wall or roof wall;

[0057] FIG. 3B the second process step for the manufacturing of a side wall or roof wall;

[0058] FIG. 3C the third process step for the manufacturing of a side wall or roof wall;

[0059] FIG. 3D the fourth process step for the manufacturing of a side wall or roof

[0060] FIG. 3E the fifth process step for the manufacturing of a side wall or roof wall;

[0061] FIG. 4A a first representation of a basic frame of a base wall according to the invention;

[0062] FIG. 4B a second representation of a basic frame of a base wall according to the invention;

[0063] FIG. 5A the first process step for the manufacturing of a bottom wall;

[0064] FIG. 5B the second process step for the manufacturing of a bottom wall;

[0065] FIG. 5C the third process step for the manufacturing of a bottom wall;

[0066] FIG. 5D the fourth process step for the manufacturing of a bottom wall;

[0067] FIG. 5E the fifth process step for the manufacturing of a bottom wall;

[0068] FIG. 5F the sixth process step for the manufacturing of a bottom wall;

[0069] FIG. 5G the seventh process step for the manufacturing of a bottom wall;

[0070] FIG. 5H the eighth process step for the manufacturing of a bottom wall;

[0071] FIG. 5I the ninth process step for the manufacturing of a bottom wall;

[0072] FIG. 6 an enveloping form of a wall according to the invention in a further embodiment;

[0073] FIG. 7 shows an enveloping form of a wall according to the invention in a further embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0074] FIG. 1 shows a base frame 2 of a wall according to the invention in plan view. The base frame comprises a plurality of braces 21, 22 which are aligned in different directions, in particular transversely to each other, and form a wall plane. In the case where the wall is a side wall, first braces 21 are oriented vertically and second braces 22 are oriented horizontally. In the case of wall elements, individual braces 22 can also be aligned at an angle to the horizontal, for example to accommodate a roof slope in the case of gable walls. In this case, the enveloping form must be designed accordingly.

[0075] 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.

[0076] FIG. 2a shows a detail of an enveloping form 3. Such an enveloping form 3 delimits an intermediate space 23 in a direction transverse to the wall plane. The enveloping form 3 comprises an outer shell 31, which covers the intermediate space 23 on a wall outer side 11, and an inner shell 32, which covers the intermediate space 23 on a wall inner side 12 (FIGS. 2b and 2c). The outer cover 31 is connected to the inner cover 32 by a plurality of connecting threads 33. When the intermediate space 23 is filled with filling material, the filling material creates an internal pressure on the outer shell 31 and the inner shell 32. The connecting threads keep the outer shell 31 and the inner shell 32 at a predefined distance from each other, so that bulges are avoided. In addition, the pressing filling material and the pulling connecting threads—analogous to reinforced concrete—can create an increased bending stiffness in the wall.

[0077] 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.

[0078] 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:

[0079] 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.

[0080] The large number of connecting threads per unit area can be seen in FIG. 2, which favours the most even possible shape of the surface on the finished wall and enables a high compressive strength of the enveloping material. A preferred number of connecting threads per unit area is in particular at least 100, preferably at least 200 or 1000 or 2000 connecting threads per square metre. The connecting threads are in each case distributed over the length X and the width y, in particular equally.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] FIG. 3 shows the steps in the manufacture of the wall in cross-section. On the outside of the wall 11 and on the inside of the wall 12, the braces 21, 22 are each provided with a double-sided adhesive tape 57 (FIG. 3a). Using the adhesive tape 57, the outer shell 31 is attached to the outside of the brace 21, 22 and the inner shell 32 is attached to the inside of the brace 21, 22 (FIG. 3b and 3c). As an alternative to the adhesive tapes, other, in particular elastic or pasty, adhesive and/or sealing media can also be used.

[0085] 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 (FIG. 3d). Even if the adhesive strength decreases due to ageing, a permanent fixation of the enveloping form to the braces is thus ensured. Staples or nails can also be used as fastening fittings for the enveloping form.

[0086] 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.

[0087] Then the space 3 is filled with the foaming filling material 4 (FIG. 3e).

[0088] FIG. 6 shows a modification of the enveloping form 3 according to FIG. 2a. The enveloping form is designed to delimit a plurality of intermediate spaces. For example, the outer shell 31 is designed integrated for several intermediate spaces. Several separate inner shells 32 are formed to delimit only one intermediate space at a time. Thus, passages 34 are provided between the individual inner shells through which the braces 22, in particular the cross braces, can be passed between two inner shells to reach their destination between the connecting threads 33. The enveloping form 3 as well as the base frame 2 can be widely pre-assembled.

[0089] The inner shell and the outer shell are then attached to the braces as previously described.

[0090] FIG. 7 shows a further modification of the enveloping form 3 according to FIG. 2a. The enveloping form is designed to delimit a plurality of intermediate spaces. Thus, the outer shell 31 and the inner shell are designed to be integrated for several intermediate spaces. There are insertion channels 35 for braces, in particular the cross braces 22, which can be passed through between connecting threads. After passing through, the passed-through braces 22 can be connected to another brace 21, in particular the vertical brace 21. In this embodiment, too, the enveloping form 3 and the base frame 2 can be widely pre-assembled. In the case of the basic frame, the vertical brace 21 must be subsequently mounted on the horizontal brace 22.

[0091] The inner cover and the outer cover are then attached to the braces as previously described.

[0092] FIG. 4a shows the base frame 2 in an embodiment of a bottom wall. The base frame 2 has first and second braces 21, 22 which are aligned in different directions and form intermediate spaces 23 between them. The intermediate spaces 23 can be further substructured by means of intermediate braces 24, as FIG. 4b shows.

[0093] FIG. 4b shows a section of a planking 55 which covers the intermediate spaces 23 during the manufacturing process of the bottom wall. The planking 55 can also be used in the design according to FIG. 4a (without intermediate braces 24).

[0094] FIG. 5 shows the further steps for producing a bottom wall 1B on an uneven ground 91.

[0095] A foil 52 is laid on the ground 91. Several ground anchors 51 are inserted into the ground (FIG. 5a). The ground anchors 51 are designed to apply a tensile force to the ground 91. When the ground anchors 51 penetrate the foil 52, the foil 52 must be sealed at the ground anchors 51.

[0096] Such a ground anchors 51 may comprise a threaded rod fixed to the ground.

[0097] A grounding fitting 53 is attached to each tie rod 51 by means of a grounding fixing 54 (FIG. 5b). The grounding fitting can be an angle fitting. The grounding fixing 54 may, for example, comprise a nut that is attached to the threaded rod. Individual braces 21, 22 of the base frame 2 from FIG. 4 are attached to the grounding fixing 54.

[0098] 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 (FIG. 5c).

[0099] Now the filling process is started (FIG. 5d). First, a first quantity of foaming filling material 41 is introduced into the intermediate space 23. The first amount is placed in edge areas of the intermediate space 23, especially in corner areas at the braces 21, 22. Areas of the grounding fixing and the fittings are also enclosed by filling material. Due to the small amount of filler material in the first filling, the individual intermediate spaces are sealed against each other and the frame undersides are sealed against the foil. The small amount of filling material prevents the base frame from being lifted by the foam pressure. The first amount of filling material 41 then hardens for a period of a few minutes.

[0100] A second amount of filling material is then introduced into the intermediate space 23 (FIG. 5e). In the area of the intermediate spaces, the ground 91 is covered with a thin layer of filling material over the entire surface. The filling material also flows into gaps between or under the braces that occur during the pressureless curing of the previous filling. These are thus closed and a good bond with the frame material is ensured. The intermediate space 23 is not completely filled. The second amount of filling material 42 then cures for a few minutes.

[0101] The above process can now be repeated as often as desired (FIG. 5f) until the filler material has reached approximately a predetermined average distance D from the upper edge O of the braces, here for example 4 cm. For example, a third amount of filler material 43 is applied to the second amount of filler material 42 and then cures for a few minutes. If parts of the cured filler material protrude above the braces, these parts can simply be cut off and placed in the space 23; these are then enclosed by the next amount of filler material.

[0102] 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.

[0103] Small final quantities of filler material 44 are now introduced through these holes 56 (FIG. 5h). This quantity now foams up and fills the intermediate space 23 completely, at least over a substantial part of the surface, up to the planking 55 at the top (FIG. 5i). It is important that the final quantity of 44 added is not too large, as otherwise the pressure from below against the planking 55 may become too great and bulges may occur.

LIST OF REFERENCE NUMERALS

[0104] 1 wall [0105] 11 wall outer side [0106] 12 wall inner side [0107] 2 base frame [0108] 21 first brace/vertical brace [0109] 22 second brace/horizontal brace [0110] 23 intermediate space [0111] 24 intermediate brace [0112] 3 enveloping form [0113] 31 outer shell [0114] 32 inner shell [0115] 33 connecting thread [0116] 34 passage [0117] 35 insertion channel [0118] 4 filling material [0119] 41 first filling quantity of filling material [0120] 42 second filling quantity of filling material [0121] 43 third filling quantity of filling material [0122] 44 final filling quantity of filling material [0123] 51 ground anchors [0124] 52 foil [0125] 53 grounding fitting [0126] 54 grounding fixing [0127] 55 planking [0128] 56 hole [0129] 57 double-sided adhesive tape [0130] 58 fastening fitting [0131] 59 wood screw [0132] D distance [0133] O upper edge of braces [0134] 91 ground [0135] 100 building