LIGHTWEIGHT CONSTRUCTION ELEMENT, MANUFACTURING METHOD THEREFOR, USE OF SAME, AND LIGHTWEIGHT PANEL AND INSULATING MATERIAL
20170183869 ยท 2017-06-29
Assignee
Inventors
Cpc classification
B32B7/03
PERFORMING OPERATIONS; TRANSPORTING
B32B21/13
PERFORMING OPERATIONS; TRANSPORTING
B32B5/16
PERFORMING OPERATIONS; TRANSPORTING
B32B2317/16
PERFORMING OPERATIONS; TRANSPORTING
B32B21/02
PERFORMING OPERATIONS; TRANSPORTING
B32B37/187
PERFORMING OPERATIONS; TRANSPORTING
B32B2305/30
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B32B3/30
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B2331/04
PERFORMING OPERATIONS; TRANSPORTING
International classification
E04C2/24
FIXED CONSTRUCTIONS
B32B5/16
PERFORMING OPERATIONS; TRANSPORTING
B32B7/00
PERFORMING OPERATIONS; TRANSPORTING
B32B37/00
PERFORMING OPERATIONS; TRANSPORTING
B32B21/13
PERFORMING OPERATIONS; TRANSPORTING
B32B3/30
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B32B3/18
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A lightweight construction element (1) comprises at least one lightweight panel (2) and a layer of insulating material (4) associated with the lightweight panel (2), wherein the at least one lightweight panel (2) comprises boards (6), which, on at least one of the main surfaces (8) thereof, have a group of grooves (9) running parallel and which boards (6) are arranged in at least one layer (5) and are connected to one another via adhesive bonds. The layer of insulating material (4) comprises wood chips (19), which are removed from starting boards during the manufacture of boards (6) for the lightweight panels (2). These lightweight construction elements have good load and thermal insulation properties. The material used originates from one source and achieves a large overall volume after processing.
Claims
1. A lightweight construction element comprising at least one lightweight panel and a layer of insulating material associated with the lightweight panel, wherein the at least one lightweight panel comprises boards, which, on at least one of the main surfaces thereof, have a group of grooves, which run parallel, and which boards are arranged in at least one layer and are connected to one another via adhesive bonds, wherein the layer of insulating material comprises wood chips, which are removed from starting boards during the manufacture of boards comprising grooves for the lightweight panel.
2. The lightweight construction element according to claim 1, wherein, at least a part of the grooves of the boards of the at least one lightweight panel have a groove width increasing away from the main surface towards the interior of the board and the webs of wood formed between these grooves accordingly becoming wider from the interior of the board towards the main surface and having a wide web surface on the main surface.
3. The lightweight construction element according to claim 1, wherein the at least one lightweight panel comprises at least two layers, and each layer is formed by boards comprising grooves, wherein the boards of each layer are connected to one another on the side edges thereof and the directly adjoining layers are connected on the main surfaces of the boards thereof via adhesive bonds, and grooves, which face one another, of different layers, which are connected to one another, run at an angle to one another.
4. The lightweight construction element according to claim 1, wherein, in at least a part of the layers the boards have on both main surfaces a group of grooves, which run parallel, and preferably a second group of parallel grooves at an acute angle to the first group grooves of this main surface.
5. The lightweight construction element according to claim 1, wherein the wood chips of the insulating material are substantially embodied in a strip-shaped and flat, corrugated, roll-shaped, spring-shaped or spiraled manner, and at least 80 percent by weight of the wood chips of the insulting material are formed by wood chips of a length in the range of between 2 mm and 40 mm.
6. The lightweight construction element according to claim 1, wherein the wood chips of the insulating material, together with a binding agent, form a substantially cohesive structure, the binding agent, comprises at least a portion of an organic binder and/or of an inorganic binder, wherein preferably the binder comprises tannin, preferably the organic binder comprises a polymer binder, preferably polyvinyl acetate (PVAc), and preferably the inorganic binder is an alkali polysilicate-based binder, preferably a mixture of sodium silicate and/or potassium silicate comprising lithium silicate.
7. A method for manufacturing a lightweight construction element comprising at least one lightweight panel and a layer of insulating material associated with the lightweight panel, wherein the at least one lightweight panel comprises boards, which, on at least one of the main surfaces thereof, have a group of parallel grooves and which are arranged in at least one layer and are connected to one another via adhesive bonds, wherein wood chips are removed from starting boards and are at least partially used to manufacture the layer of insulating material, where the boards with grooves are joined to form at least one layer of the lightweight panel.
8. The method according to claim 7, wherein at least one cavity, into which the wood chips are filled preferably together with a binding agent for manufacturing the layer of insulating material, is formed on the lightweight construction element between the at least one lightweight panel and at least one further panel, wherein the wood chips and the binding agent are preferably in each case oppositely charged electrically during the filling of the cavity, so that a mixing, which is as complete as possible, is ensured thereby.
9. The method according to claim 7, wherein wood chips are applied in a layered manner via at least one application device to a carrier belt so as to manufacture the layer of insulating material, a binding agent is applied to the wood chips (19) via a nozzle arrangement, and a pressing belt presses the wood chips, which are provided with the binding agent, against the carrier belt on a hardening path, wherein the carrier belt and/or the pressing belt preferably has separating elements for separating sections of the layer of insulating material, and preferably the wood chips and the binding agent are oppositely charged electrically for application or impacting, respectively, so that a mixing, which is as complete as possible, is ensured thereby.
10. The method according to claim 7, wherein, based on 1 m.sup.3 of wood in the form of raw boards of a weight of substantially 450 kg, 30 to 60 percent by weight, preferably substantially 180 kg of this wood material ends up in lightweight panels, the cavity portion of which is preferably in a range of between 30% and 50%, and that between 100 kg and 270 kg, preferably substantially 200 kg, of the removed residual material is used for the production of insulating material, wherein the density of the insulating material is in the range of between 60 and 90 kg/m.sup.3 and insulating material with a volume in the range of between 1.5 m.sup.3 and 3.5 m.sup.3 is preferably provided in the lightweight construction panels in addition to the wood material.
11. A lightweight panel comprising boards or comprising sections of boards, which boards or sections, respectively, have a group of grooves, which run parallel on at least one of the main surfaces thereof and are arranged in at least one layer and are connected to one another, wherein, at least a part of the grooves of the boards or sections, respectively, of the at least one lightweight panel, have a groove width increasing away from the main surface towards the interior of the board or section, respectively, and the webs of wood formed between these grooves accordingly becoming wider from the interior of the board or section, respectively, towards the main surface, and having a wide web surface on the main surface.
12. The lightweight panel according to claim 11, the lightweight panel comprising at least two layers and each layer is formed by boards comprising grooves, wherein the boards of each layer are connected to one another on the side edges thereof and the directly adjoining layers are connected on the main surfaces of the boards thereof via adhesive bonds, and grooves, which face one another, of different layers, which are connected to one another, run at an angle to one another.
13. The lightweight panel according to claim 11, wherein in at least a part of the layers the boards have a group of grooves running parallel on both main surfaces, and a second group of parallel grooves is preferably formed at least on one main surface at an acute angle to the first group of grooves of this main surface.
14. The lightweight panel according to claim 11, wherein cut short sections of the same length of lightweight panels, where the main surfaces of the boards run parallel to the outer surface of the lightweight panel, are rotated by 90, are arranged next to one another in one layer and are brought into mutual connection with the partial surfaces of the outer surfaces of the divided lightweight panels, so that they form a layer of sections, wherein the cut surfaces of the connected sections form the outer surfaces of the layer of the short sections and a cover layer is preferably arranged on at least one of these outer surfaces.
15. (canceled)
16. An insulating material comprising wood particles and binding agent, wherein the wood particles are wood chips, which are removed from starting boards during the manufacture of boards (6) comprising grooves, wherein the wood chips are substantially embodied in a strip-shaped and flat, corrugated, roll-shaped, spring-shaped or spiraled manner, and at least 80 percent by weight of the wood chips of the insulting material are formed by wood chips of a length in the range of between 2 mm and 40 mm and the wood chips, together with the binding agent, form a substantially cohesive structure, the binding agent comprises at least one portion of an organic binder and/or of an inorganic binder, wherein the binder preferably comprises tannin, the organic binder preferably comprises a polymer binder, preferably polyvinyl acetate (PVAc), and the inorganic binder is preferably an alkali polysilicate-based binder, preferably a mixture of sodium silicate and/or potassium silicate comprising lithium silicate.
Description
[0082] The invention will be specified in more detail by means of the drawing.
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[0097] The boards 6 have a group of grooves 9, which run parallel, at least on one of the main surfaces 8 thereof (see
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[0099] In the illustrated embodiment, each lightweight construction element 1 comprises two grooves 3b, which are embodied in a mirror-inverted manner relative to a central plane of the lightweight construction elements 1 on two groove parts 3, which are connected to one another. The clamping device preferably comprises at least one arrangement comprising two clamping elements 30a, which are formed in a mirror-inverted manner and which can be moved towards one another by means of at least one clamping screw 30b, wherein guide surfaces 30c of the clamping elements 30a run in engagement with matching groove surfaces at an acute angle to the screw axis and are oriented in such a way that the lightweight construction elements 1, which are to be connected, are moved into the desired contact position by means of the forces acting on the groove surfaces when the clamping elements 30a move towards one another.
[0100] The axes of the clamping screws 30b are at right angles, in particular substantially vertically, to the large outer surfaces of at least one of the two lightweight construction elements 1 and can be operated from one side of the lightweight construction element 1. When the tight connection is fixed by means of an adhesive, the clamping screws can be removed after the adhesive has hardened, and a connection, which is free from metallic elements, is created. If the desired connection is embodied so as to be firm, the clamping device can be provided with an insulating material, if necessary, which is not illustrated, in particular with an insulating strip, and can be covered by means of cover strips 30d. The cover strips are introduced between the large edge surfaces of the connected lightweight construction elements 1.
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[0102] In a first non-illustrated processing area, circular saw blades of the same size are arranged on a shaft, which is oriented parallel to the main surface 8 of the boards 6 and vertically to the longitudinal board direction. The central area of the grooves 9 is embodied by means of these circular saw blades. If the grooves are formed on both main surfaces 8 of the boards 6, a shaft comprising circular saw blades of the same size is used above and below the boards.
[0103] In a second processing area, a shaft 11 is used, which is oriented at an acute angle to the main surface 8 to be processed of the boards 6 and on which circular saw blades 10 comprising an increasing diameter are arranged at predetermined intervals. The shaft 11 is located in a plane, which stands vertically on the main surface 8 of the boards 6 and which is oriented vertically to the longitudinal axes of the grooves 9. The angle between the shaft 11 and the main surface 8 as well as the diameters of the circular saw blades 10 and the positions thereof on the shaft 11 are matched to one another in such a manner that all circular saw blades form grooves of substantially the same depths. Due to the inclined shaft 11, a disk angle =90 is formed between the planes of the circular saw blades 10 and the main surface 8.
[0104] According to the incline of the circular saw blades or of the disk angle , respectively, the disk angle is also formed between the lateral edge surfaces of the grooves 9, which are created, and the main surface 8 of the board 6. So that the grooves 9 do not maintain the asymmetric form in sectional planes vertically to the longitudinal groove direction, a further shaft 11, which comprises circular saw blades 10 and which is oriented at a further acute shaft angle to the main surface 8 of the boards 6, is assigned to the same main surface 8 according to
[0105] The processing by means of the inclined shafts 11 and the circular saw blades 10 of different sizes, which are fastened thereto, preferably takes place on both main surfaces 8 of the boards 6, thus from above and from below.
[0106] The used shafts 11 comprising the circular saw blades 10 are matched to one another in such a manner that substantially symmetrical groove cross sections are present after the processing of a main surface 8 with all shafts 11, wherein the groove width becomes larger away from the main surface 8 towards the interior of the board 6. The groove opening on the main surface 8 corresponds at least to the expansion of the circular saw blades 10 in the main surface 8 vertically to the longitudinal groove direction. Webs 14 of wood, which become wider from the interior of the board 6 towards the main surface 8 and which have a wider web surface 15 on the main surface 8, remain between the grooves 9. These wide web surfaces 15 ensure sufficiently large contact surfaces for a stable adhesive bond by gluing layers 5, and this independent from the angle between the grooves 9 in the adjoining main surfaces 8 of the two layers 5.
[0107] A central cohesive wood layer 13 can absorb forces, which are applied into the grooved board 6 via the side edges 7. After the gluing of layers comprising grooves, which are oriented differently, these transverse forces are absorbed by the webs 14 of the adjoining layer 5, because these webs 14 run aslant to the side edges 7 of the boards 6 of the first layer 5.
[0108] The boards 6 of
[0109] According to
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[0113] The sections illustrated in
[0114] In the embodiment according to
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[0119] In addition to the walls according to
[0120] At both of the lightweight panels 2, which are to be connected, the illustrated connecting device 34 comprises frame parts 3, which engage with second groove tongue arrangements 5a of the lightweight panels 2 by means of the first groove tongue arrangements 3a, wherein these engaging groove tongue arrangements 3a, 5a are glued to one another. So that the lightweight panels 5 can also be connected to one another easily at a construction site, the frame parts 3 have the connecting grooves 3b. Connecting strips 35 comprising groove tongue arrangements 35a make it possible to fixedly connect the frame parts 3 of the lightweight panels 2, which face one another, by using adhesives and/or connecting elements. If necessary, a cavity, which can be used for guiding of wirings, is created between the connecting strips 35 inserted from both sides.
[0121] It goes without saying that such interior walls can be covered or coated on one side or also on both sides. If necessary, a covering is held at a desired distance to the lightweight panels by spacers, so that a cavity, which can be used for installation purposes or for accommodating sound insulating material, for example, results between the lightweight panels and the covering.