APARTMENT BUILDING AND METHOD FOR MANUFACTURING THERMAL INSULATION

Description

[0001] The invention relates firstly to an apartment block with the features of claim 1 and a method for producing thermal insulation according to claim 14.

[0002] The impact sound insulation mechanically decouples the floor from the surface of the outer shell, thus reducing the transmission of walking noise to neighboring, especially lower-lying, residential units.

[0003] Shipping containers (also known as "ISO containers", especially according to ISO 668) are standardized cuboid-shaped large-capacity containers made of steel that allow for easy and quick loading, transport, storage and unloading of goods.

[0004] Upcycling used shipping containers into residential units requires high-quality interior insulation – both to ensure a high standard of living and to minimize energy consumption. To prevent thermal bridges caused by both metallic connections and joints, monolithic, seamless thermal insulation panels are used, supporting the floor, ceiling, and walls.

[0005] DE 20 2008 002 754 U1 proposes a residential block made of recycled ISO steel containers with thermal insulation consisting of prefabricated insulation panels. In practice, thermal bridges between the prefabricated insulation panels are unavoidable. Condensation collects on the inside of the containers – especially when they form the outer shell of the residential block – which promotes bacterial growth and impairs the thermal insulation.

[0006] GB 2472761 A discloses the features of the preamble of claim 1 and proposes spraying polyurethane rigid foam thermal insulation onto the interior walls of a residential unit made from a recycled ISO steel container, embedding fastening elements in the insulation, and screwing the floor, ceiling, and walls to these fastening elements. The fastening elements embedded in the thermal insulation locally reduce its insulating effect.

[0007] In the background of the invention, DE 2 221 486 A proposes to first build an inner shell made of glass fiber reinforced PE resin on a core for a caravan body and a mold around this, to fill the cavity with PU foam as thermal insulation and, after removing the mold, to build an outer shell again made of GF-reinforced PE resin.

[0008] In further background to the invention, EP 0 367 275 A1, US 6,920,996 B1 and US 5,733,582 A each propose, for the manufacture of an insulated container, to first manufacture side walls, roof and floor individually as a "sandwich" and then join them together, to attach spacers between the inner and outer shell or to clamp the container and a prefabricated inner shell between an outer support frame and a mandrel and tilt it in different directions in order to allow the still liquid foam for thermal insulation to flow in the desired direction. Task

[0009] The invention is based on the objective of improving the thermal insulation of the residential unit. Solution

[0010] Based on the known residential block, the invention proposes that the thermal insulation completely fills the cavity and is bonded to the ceiling and walls. This bonding replaces both the substructure required for reinforcing drywall partitions (in traditional drywall construction, this is achieved through timber framing or metal profiles) and the fastening of the ceilings and walls to the substructure using form-fitting and force-fit fasteners such as screws or nails. In particular, the thermal insulation can be injected into the cavity, bonding it completely to the ceiling and walls, or the ceiling and walls can be subsequently bonded to the thermal insulation. Hybrid forms are also conceivable.

[0011] Preferably, the thermal insulation of a residential block according to the invention consists essentially of a rigid polyurethane foam, in particular a closed-cell foam. The thermal insulation then contributes significantly to the mechanical stability of the ceiling and the walls.

[0012] Alternatively, the thermal insulation can essentially consist of a loose fill or free-flowing material - for example, wood fibers, expanded glass, perlite or a silica aerogel - with a foaming and hardening or fixing component.

[0013] The thermal insulation can also be constructed in layers from a combination of the aforementioned materials.

[0014] The thermal insulation can also include at least one layer of vacuum insulation panels ("VIP insulation"). In this case, the thermal insulation has a particularly high insulation value.

[0015] Preferably, in a residential block according to the invention, the walls and / or the ceiling of the rooms comprise at least one layer of an elastic material – in particular an open-cell elastomeric foam or mineral wool in panel form. The elastic material reduces the transmission of structure-borne sound between the building envelope and the interior.

[0016] Preferably, in a residential block according to the invention, the walls, floor, and ceiling of the residential unit have a mineral-bonded surface layer on an interior surface facing the interior. A mineral-bonded surface layer, in particular made of gypsum plasterboard or fiberboard, allows for interior finishing using technologies that have been known for generations and are cost-effective. Alternatively, the floor, walls, and ceiling can also be made of a wood-based material, for example, three-layer panels. Hybrid forms are also conceivable.

[0017] In particular, in a residential block according to the invention, the floor of the residential unit can comprise a dry screed, if the dry screed has a surface weight of at least 50 kg / qm It also acts as a heat buffer and reduces the heating requirements of the residential unit.

[0018] In a residential block according to the invention, the walls, floor, and ceiling of the residential unit can have a vapor barrier layer on an exterior surface facing the thermal insulation. The vapor barrier significantly reduces the moisture absorption of the thermal insulation—in particular, a hygroscopic rigid polyurethane foam—through the walls, thus preserving the insulating properties of the thermal insulation.

[0019] Preferably, in a residential block according to the invention, the floor of the residential unit has underfloor heating. Underfloor heating eliminates the need for additional radiators and ensures a particularly high level of living comfort. Alternatively, the walls or ceiling of the room can also be designed as heating surfaces. Hybrid forms are also conceivable.

[0020] Preferably, in a residential block according to the invention, the shell of the residential unit is a shipping container. In particular, used shipping containers are available in large – and increasing – numbers at low cost as raw material, are characterized by a very robust, especially extremely weather-resistant surface, and can be reintroduced into the material cycle as a high-quality raw material even after many years of reuse as residential units.

[0021] Preferably, in a residential block according to the invention, the shell of the residential unit has a length of approximately 12 m and a height of approximately 2.90 m. Such a "40-foot container" (so-called "high cube" or "HC container") enables a usable living area of ​​up to 26 m². qm. Alternatively, for smaller living units, shipping containers with a length of 20' can be considered, for larger units 45' or 53', or in the case of less elaborate floor and ceiling constructions of the living space with a height of about 2.60 m.

[0022] Preferably, in a residential block according to the invention, the outer shell and the interior walls of the residential unit are perforated, in particular by at least one door opening and / or window opening, such that the interior is connected to an external environment of the shell. Alternatively, a residential unit according to the invention can also be accessed from below via stairs or an elevator through the floor area or from above through the roof. Hybrid forms are also conceivable.

[0023] In a residential block according to the invention, the thermal insulation of the residential unit naturally does not fill the door and window openings, nor openings in the outer shell for stairs, elevators, and supply or disposal lines. Within the scope of this application, these openings are not considered part of the outer shell, and the volumes adjoining them to the interior are not considered part of the cavity.

[0024] Preferably, in a residential block according to the invention, the outer shell of the residential unit has a passageway running parallel to one end face, and the interior is separated from the passageway by an interior wall. Integrating the passageway into the outer shell simplifies the combination of several such residential units. Alternatively—or additionally—such a residential unit can have an outward-facing terrace or balcony on the same or the opposite end face.

[0025] Preferably, in a residential floor of a residential block according to the invention, the interior spaces of adjacent residential units are connected by the perforated shells and room walls. Such a combination of residential units creates contiguous rooms whose living area exceeds the space available in a single container.

[0026] Preferably, on such a residential floor, the passageways of adjacent residential units connect to each other and form a common corridor.

[0027] Preferably, in a residential block according to the invention, corridors of vertically arranged residential floors are connected by stairs and / or elevators. Residential units arranged side-by-side and one above the other according to the invention can also be accessed via an independent extension. Hybrid forms are also conceivable.

[0028] Based on the known method, the invention proposes that, first, an inner surface of the interior wall, facing the interior, is supported by a core, and an outer surface of the exterior wall, facing the external environment of the container, is supported by a support device perpendicular to the inner surface. Then, the foam is injected, and after the foam has hardened, the core is removed from the inner surface and the support device from the outer surface. By supporting the interior wall and the exterior wall, deformation of these surfaces is effectively prevented.

[0029] Preferably, in a method according to the invention, the interior wall is attached to the core, positioned parallel to the outer wall together with the core before the foam is injected, and detached from the core for removal. The core then additionally assumes the function of a handling device for the interior wall. The method according to the invention thus eliminates the need to attach the interior wall to the outer wall before the foam is injected.

[0030] In this method according to the invention, the partition wall is attached to the core by means of a vacuum. The attachment of panel-shaped building elements to handling devices by means of a vacuum is, for example, well known from the handling of OSB, three-layer, and particleboard in the carpentry trade. After the foam has been injected and hardened, the partition wall is detached from the core by releasing the vacuum.

[0031] Preferably, in a method according to the invention, the foam is injected in vertically stacked layers. In the method according to the invention, the foam then fills and compensates for unevenness in the surface of the lower layer during injection under the influence of gravity. Alternatively, in a method according to the invention, the foam is injected simultaneously from several horizontally arranged nozzles, which may oscillate in the longitudinal direction of the room wall during injection and are thereby continuously raised.

[0032] Preferably, in a method according to the invention, the foam is injected simultaneously between a second internal wall and a second external wall, wherein the internal wall is arranged opposite the second internal wall in the interior, and the external wall is formed on the container opposite the second external wall. The core and the support device thus support each other during the injection of the foam. The method according to the invention therefore essentially eliminates the need for external support of both the core and the support device.

[0033] Preferably, in a method according to the invention, the foam is injected between a ceiling enclosing the room and a lid enclosing the container, following the production of thermal insulation between the room wall and the outer wall. The method according to the invention thus also allows for thermal insulation of the ceiling.

[0034] Preferably, in a method according to the invention, the injection of the foam between the interior wall and the exterior wall is documented using a camera. The method according to the invention is thus documented for quality control of the thermal insulation.

[0035] Preferably, a method according to the invention is used in the production of a residential unit for a residential block described above according to the invention. The method according to the invention allows the industrial production of a residential unit with high dimensional accuracy, which significantly simplifies the finishing work of the residential unit. Examples of implementation

[0036] The invention is explained below with reference to exemplary embodiments. The first residential unit 1 according to the invention, shown in the drawing, has an outer shell 2 made of a 40-foot high-density shipping container and a cuboid interior space 3 therein, as well as a space 4 with thermal insulation 5 between the shell 2 and the interior space 3.

[0037] The outer shell 2 has a horizontally extending platform 6, above which, parallel to the platform 6, is a lid 7, two side walls 8, and two end walls 9, 10. The side walls 8 are pierced by two door openings 11, and the front end wall 9 is designed as a fall protection barrier. The interior 3 has a walkable floor 12, above which, parallel to the floor 12, is a ceiling 13 and four vertical walls 14, 15.

[0038] The room walls 14, 15, the floor 12 and the room ceiling 13 each have gypsum fiberboards as a mineral-bonded covering layer, which is limited to the thermal insulation 5 by a pressure-resistant vapor barrier layer 16 made of aluminium.

[0039] To construct residential unit 1, the room walls 14, 15 and the room ceiling 13 are attached to a core (not shown) by means of negative pressure and inserted, along with the core, into the previously cleared shell 2. The shell 2 is clamped from the outside in a support device (also not shown).

[0040] Then, for thermal insulation 5, a rigid polyurethane foam is injected at a pressure of over 200 bar, first simultaneously between the two room walls 14, 15 and the shell 2 in vertically superimposed layers and subsequently between the room ceiling 13 and the shell 2 in adjacent layers, using two spray devices which are also not shown.

[0041] After the thermal insulation 5 has hardened, the negative pressure is released, thereby detaching the core from the room walls 14, 15 and the 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 released.

[0042] After the installation of the floor 12 with a prefabricated panel thermal insulation, impact sound insulation and underfloor heating 18, the residential unit 1 is ready for interior finishing.

[0043] The space 4 between the lid 7 and the ceiling 13, and between the side walls 8, the rear end wall 10, and the room walls 14, is filled completely and without gaps with monolithic thermal insulation 5 made of rigid polyurethane foam. The thermal insulation 5 is connected to both the ceiling 13 and the

[0044] The room walls 14 are fully bonded to the shell 2 and also enclose the front room wall 15 of the interior space 3, which at the same time forms a partition wall 19 to a passage 20 integrated into the residential unit 1 between the two door openings 11.

[0045] The interior space 3 of the residential unit 1 according to the invention has a usable living area of ​​9.5 m × 2.2 m = 20.9 qm with a room height 21 of 2.4 m. The residential unit 1 according to the invention has excellent sound insulation values, meets the passive house energy standard and is largely recyclable. Several residential units 1 can be arranged in such a way that the door openings 11 of adjacent residential units 1 overlap and the passageways 20 form a common gallery.

[0046] A second, third, fourth, and fifth residential unit produced according to the invention are not shown, but each corresponds essentially to the first residential unit 1. The second residential unit does not have a passageway for a gallery, but instead has a usable living area of ​​12 m x 2.2 m = 26.4 qm The third residential unit is intended for installation in a stack of residential units manufactured according to the invention and has no thermal insulation between the floor and the ground as well as between the lid and the ceiling.

[0047] The fourth and fifth residential units do not have a vapor barrier, but an elastic layer of mineral wool bonded to the gypsum fiberboard, which acoustically decouples the interior from the building envelope and thus from the surroundings or adjacent residential units: In the fourth residential unit, the rigid polyurethane foam borders directly on the mineral wool, while the fifth residential unit has a prefabricated double gypsum fiberboard with an intermediate layer of mineral wool, which simplifies handling. The character is

[0048] 1 Residential unit 2 Outer shell 3 Interior space 4 Cavity 5 Thermal insulation 6 Floor space 7 Cover 8 Wall 9 Front end wall 10 Rear end wall 11 Door opening 12 Walkable floor 13 Ceiling 14 Room wall 15 Front room wall 16 Vapor barrier 17 Impact sound insulation 18 Underfloor heating 19 Partition wall 20 Passage 21 Room height

Claims

1. A residential block consisting of residential storeys arranged one above the other, at least one of the residential storeys comprising mutually adjacent residential units (1) having: an outer shell (2) consisting of a cuboid container which has a bottom surface (6), a top (7), up to two lateral walls (8) and up to two end walls (9, 10); a cuboid interior (3) which has an edge length of at least 2 m in each case, a floor (12) which can be walked on with footfall sound insulation (17), a room ceiling (13) and up to four room walls (14, 15), the room walls (14, 15) being plasterboard walls; an intermediate space (4) formed between the top (7) and the walls (8) on one side and the room ceiling (13) and the room walls (14) on the other side; and monolithic thermal insulation (5) in the intermediate space (4), characterised in that the thermal insulation (5) completely fills the intermediate space (4) and is adhesively bonded to the room ceiling (13) and the room walls (14) such that the thermal insulation (5) replaces a substructure for reinforcing the plasterboard walls.

2. The residential block according to the preceding claim, characterised in that the thermal insulation consists of a polyurethane hard foam, in particular with closed pores.

3. The residential block according to any one of the preceding claims, characterised in that the room walls (14) and / or the room ceiling (13) have at least one layer of an elastic material.

4. The residential block according to any one of the preceding claims, characterised in that the room walls (14, 15), the floor (12) and / or the room ceiling (13) have a mineral-bound top layer on an inner side facing the interior (3) and / or are implemented in a wood-based material.

5. The residential block according to the preceding claim, characterised in that the floor (12) comprises a dry screed, preferably with a weight per unit area of at least 50 kg / m2.

6. The residential block according to any one of the preceding claims, characterised in that the floor (12) has a floor heating system (18).

7. The residential block according to any one of the preceding claims, characterised in that the shell is a sea container.

8. The residential block according to the preceding claim, characterised in that the shell (2) has a length of 12 m and a height of 2.90 m.

9. The residential block according to any one of the preceding claims, characterised in that the shell (2) and the room walls (14, 15) are perforated such that the interior is connected to an external environment of the shell.

10. The residential block according to the preceding claim, characterised in that the interiors of adjacent residential units are connected through the perforated shells (2) and room walls (14, 15).

11. The residential block according to any one of the preceding claims, characterised in that the outer shell (2) has, at one end, a passage (20) running parallel to the end, and the interior (3) is separated from the passage (20) by a partition.

12. The residential block according to the preceding claim, characterised in that the passages (20) of the residential units (1) adjoin one another and form a corridor.

13. The residential block according to the preceding claim, characterised in that the corridors of the residential storeys are connected by stairs and / or lifts.

14. A method for producing thermal insulation (5) between a room wall (14) of a cuboid interior (3) and an outer wall (8) parallel to the room wall (14), the interior (3) having an edge length of at least 2 m in each case, and the outer wall (8) being formed on a cuboid container which encloses the interior (3), in which method an inner face, facing the interior (3), of the room wall (14) is first fastened to a core, positioned together with the core parallel to the outer wall (8) before the foam is injected, and an outer face, facing the external environment of the container, of the outer wall (8) is supported perpendicular to the inner face by means of a supporting device, then a curing foam is injected between the room wall (14) and the outer wall (8), and, after the foam has cured, the core is removed from the inner face and the supporting device is removed from the outer face, characterised in that the room wall (14) is a plasterboard wall which is fastened to the core by negative pressure, wherein the thermal insulation (5) replaces a substructure for reinforcing the plasterboard wall.

15. The method according to the preceding claim, characterised in that the foam is injected in layers running vertically over one another.

16. The method according to one of Claims 14 or 15, characterised in that the foam is injected simultaneously between a second room wall (14) and a second outer wall (8), wherein the room wall (14) is arranged in the interior (3) opposite the second room wall (14), and the outer wall (8) is formed on the container opposite the second outer wall (8) .

17. The method according to any one of Claims 14 to 16, characterised in that the foam is then injected between a room ceiling (13) closing the room at the top and a top (7) closing the container at the top.

18. The method according to any one of Claims 14 to 17, characterised in that the injection of the foam between the room wall (14) and the outer wall (8) is documented by means of a camera.

19. A method for producing a residential unit (1) for a residential block according to any one of Claims 1 to 13, characterised in that the thermal insulation (5) is produced according to any one of Claims 14 to 18.