LIGHTWEIGHT ELEMENT

Description

[0001] The present invention relates to a building element comprising at least two fiber-cast nub mats. BACKGROUND OF THE INVENTION

[0002] In addition to concrete and brick, the traditional building materials in construction, lightweight materials, especially wood-based ones, are increasingly being used. Compared to concrete or brick, lightweight materials offer a weight advantage and are also more sustainable, as part of the lightweight material is made from renewable raw materials such as wood. This makes houses made of wood preferable from an ecological and economic perspective to those made of concrete or brick. As a renewable, natural building material, wood is harmless to health, CO2-neutral, easy to work, lightweight, and has good thermal insulation properties.

[0003] WO 2018 / 100058 A1 describes a wall element for construction, featuring solid wood panels connected by crosspieces, forming a cavity between the solid wood panels. The cavity is filled with an insulating material. Fiber-cast dimple mats are provided on the outer surface of the solid wood panels.

[0004] EP0923449B1 discloses a building element comprising two fiber-cast dimpled mats, wherein the fiber-cast dimpled mats have a plurality of elevations, wherein the elevations are arranged in a checkerboard pattern in horizontal rows and vertical rows, wherein grooves are formed between the elevations, wherein the first fiber-cast dimpled mat is applied to the second fiber-cast dimpled mat in such a way that the upper sides of the elevations of the first fiber-cast dimpled mat and the upper sides of the elevations of the second fiber-cast dimpled mat face each other and are aligned, wherein the first fiber-cast dimpled mat and the second fiber-cast dimpled mat are connected to each other.

[0005] Due to rising raw material prices for wood, there is a need for lightweight construction materials that require less wood or no wood at all, yet still retain the same positive properties as wood. Wood has favorable properties relative to its own volume, which are only achieved with known substitute materials at significantly larger volumes. BRIEF DESCRIPTION OF THE INVENTION

[0006] The object of the present invention is therefore to provide a lightweight construction material that has comparable properties to wood and is as ecologically sound as wood, but does not require significant amounts of wood. In particular, there is a need for a wood substitute material that has comparable values ​​in terms of strength, load-bearing capacity, and rigidity to wood while requiring comparable or reduced volume and mass.This object is achieved by a building element comprising at least two fiber-cast dimpled mats, wherein the fiber-cast dimpled mats have a plurality of elevations, wherein the elevations are arranged in a checkerboard pattern in horizontal rows and vertical rows, wherein grooves are formed between the elevations, wherein the first fiber-cast dimpled mat is applied to the second fiber-cast dimpled mat in such a way that the upper sides of the elevations of the first fiber-cast dimpled mat and the upper sides of the elevations of the second fiber-cast dimpled mat face one another and are aligned, wherein the first fiber-cast dimpled mat and the second fiber-cast dimpled mat are connected to one another, wherein reed-like grasses are introduced into the grooves.

[0007] The inventor has discovered that a structural element according to the invention has the same strength, load-bearing capacity and rigidity as solid wood with the same thickness and, in addition, exhibits higher thermal and sound insulation with lower mass.

[0008] Reed-like grasses are not sufficiently stable as a building element on their own. However, when they are incorporated into the grooves or channels of fiber-cast dimpled mats, the targeted alignment and additional stabilization provided by the fiber-cast dimpled mat improve all of the building element's properties. The reed-like grasses are renewable resources, and the fiber-cast dimpled mats are also made from renewable resources, making them environmentally safe. The building element is therefore recyclable, CO2-neutral, and self-supporting.

[0009] For example, fiber-cast dimpled mats are already described in DE 10 2014 221 425 A1. The building elements described in DE 10 2014 221 425 A1 comprise a fiber-cast dimpled mat as an intermediate layer, although the fiber-cast dimpled mat is not load-bearing without an additional wood layer. To increase the stability of the fiber-cast dimpled mat, DE 10 2014 221 425 A1 proposes webs between the raised portions. However, these webs are not capable of stabilizing the fiber-cast dimpled mat to such an extent that a self-supporting building element results.

[0010] Preferably, the structural element does not require any wooden reinforcement, e.g. in the form of wooden panels or the like.

[0011] In a first embodiment, the first fiber-cast dimpled mat and the second fiber-cast dimpled mat can be connected to each other via an intermediate layer, wherein the intermediate layer is connected, preferably glued, to the upper surfaces of the raised portions. This increases the torsional rigidity of the component. The intermediate layer is preferably made of the same material as the fiber-cast dimpled mat.

[0012] Another design variant provides for the grooves of the first fiber-cast dimpled mat and the grooves of the second fiber-cast dimpled mat to jointly form channels, with the reed-like grasses being inserted into the channels formed by the grooves of the first fiber-cast dimpled mat and the grooves of the second fiber-cast dimpled mat. This design variant has the advantage that the structural element remains more stable and suffers less damage when shear forces occur.

[0013] In one design variant, the reed-like grasses are placed in a coiled tube, with the coiled tube containing the reed-like grasses being inserted into the gutters or, if channels are present, into the channels themselves. This further increases stability and simplifies production, as the reed-like grasses are bundled in the coiled tube before being inserted into the gutters or channels. The coiled tube can be made of cardboard or molded fiber material, for example.

[0014] Preferably, the reed-like grasses are selected from the group consisting of Miscanthus × giganteus, Phragmites australis (common reed), Arundo donax (spine reed) or mixtures thereof, particularly preferred from Miscanthus × giganteus consist. Miscanthus × giganteus is not only extremely stable, but also inexpensive to produce.

[0015] In addition to the reed-like grasses, additional stiffening elements can also be incorporated into the channels. Examples of stiffening elements include cardboard, honeycomb board, solid wood, or plastic plates, with renewable materials being preferred, i.e., cardboard, honeycomb board, and / or solid wood.

[0016] Reed-like grasses are used in the prior art for reed insulation mats, but they do not serve as structural stabilization, but rather solely as thermal insulation elements. In reed insulation mats, the reed-like grasses are bound with steel wire, which presents the significant disadvantage of being difficult to cut. Furthermore, the reed-like grasses are compressed so tightly that they often break at the binding point. These disadvantages are avoided with the present invention.

[0017] The elevations can be cylindrical, circular-cylindrical or cuboid-shaped, for example.

[0018] However, it is particularly preferred that the elevations have the shape of a substantially square, regular truncated pyramid.

[0019] Furthermore, it can be provided that the first fiber-cast knob mat and the second fiber-cast knob mat are connected, preferably glued, to one another at the upper sides of the elevations.

[0020] Preferably, the fiber-cast dimpled mats comprise cellulose. Cellulose is a natural material that is easy to process and also offers good structural properties. Additionally, a layer of plaster can be applied to the fiber-cast dimpled mats. Cellulose can be obtained from waste paper, renewable fibers such as hay, straw, hemp, or similar materials. Therefore, the cellulose content is preferably at least 90% by weight, particularly preferably at least 95% by weight, in order to be able to process a high degree of recycled material and sustainable raw materials.

[0021] The fiber-cast dimpled mats can be made from fiber-cast material. The starting point is natural fibers (cellulose), which can come from packaging cardboard or punching waste from the production of packaging cardboard, for example. This cellulose is mixed with water and then pressed into the shape of a dimpled sheet using molds. The dimpled sheet is dried and sterilized by heating to 180°C. Typically, the dimples have a height between 8 and 60 mm, preferably between 30 and 40 mm. The subsequently applied plaster layers can, for example, be between 15 and 30 mm. The dimple height, shape, and arrangement can be manufactured in other dimensions as required.

[0022] Graphite can also be stirred into the base material for the fiber-cast dimpled mats, the fiber pulp. Therefore, the fiber-cast dimpled mats can contain graphite. The proportion is preferably 3 to 6 wt.% based on the fiber-cast material. The graphite acts as a heat radiation absorber, reducing heat radiation through the fiber-cast mat. The graphite particles in the fiber cast reduce the absorption and reflection of heat radiation.

[0023] Additionally, pipes, particularly for heating and cooling a wall, can be laid between individual rows of elevations. The matrix for the necessary pipes is already present in the structural element through the elevations and grooves. Furthermore, the cavities of the studded panel can be filled from the rear with a latent material. The same latent material, mixed into plastering material (such as clay, lime, or gypsum), can be used to plaster the front of the studded panel. Overall, this can significantly reduce the required heating energy in winter or cooling energy in summer.

[0024] Thermal radiation is usually invisible light in the infrared radiation range, which also penetrates a plastered surface.

[0025] The fiber-cast dimpled mats can also have a graphite coating, particularly preferably in the form of a full-surface graphite coating. A graphite coating is an electrically conductive, radiation- and heat-shielding surface coating. Graphite mixtures can provide properties related to fire protection, thermal conductivity, or even improved plaster support properties. A high graphite content in the coating gives the fiber-cast dimpled mats very good thermal conductivity. Heat is evenly distributed across the surface and efficiently transferred to the plaster layer. This creates a completely homogeneous thermal image with no temperature differences. The graphite coating is particularly preferably made of expandable graphite (expanding graphite). Expandable graphite expands at higher temperatures and then acts as an intumescent coating in the event of a fire.

[0026] In one embodiment, two additional fiber-cast dimpled mats can be provided as previously defined, with the two additional fiber-cast dimpled mats being glued to the first fiber-cast dimpled mats. The two additional fiber-cast dimpled mats are each glued to each other on the back sides.

[0027] Furthermore, it can be provided that a plaster base plate is attached to at least one fiber-cast dimpled mat. Particularly preferably, a plaster base plate is attached to each of the two fiber-cast dimpled mats. This allows the building element to be a finished wall component.

[0028] In addition, a flowing screed slab can be attached to at least one fiber-cast studded mat. In this case, the component is suitable as a floor slab.

[0029] The component is characterized by a thermal conductivity that is lower than that of a solid wood panel. Typically, the component also has a lower density than a corresponding solid wood panel. DETAILED DESCRIPTION OF THE INVENTION

[0030] Fig. 1a, 1b show a top view ( Fig. 1a ) and in side view ( Fig. 1b ) a fiber-cast dimpled mat. Figs. 2 to 6 show six embodiments of components according to the invention in side views.

[0031] Fig. 1a and 1bshow a top view and side view, respectively, of a fiber-cast knobbed mat 2 with elevations 4, 4', 4". The fiber-cast knobbed mats 2 consist essentially of cellulose. The elevations 4, 4', 4" are arranged in a checkerboard pattern, ie in horizontal rows and vertical rows. In the context of the invention, a checkerboard pattern arrangement of the elevations 4, 4', 4" means that the elevations are arranged like the fields of a chessboard, with an elevation being provided on each field of the chessboard.

[0032] Between the elevations 4, 4', 4", grooves 6, 6', 6"; 7, 7', 7" are formed. Some grooves 6, 6', 6" and 7, 7', 7" are thus arranged parallel to each other. Some grooves 6, 6', 6" are arranged at right angles to other grooves 7, 7', 7".

[0033] In the illustrated embodiment, the elevations 4, 4', 4" have a cuboid base. A projection in the form of a regular square truncated pyramid is arranged on this base. The top surface of the truncated pyramid forms the upper side 10 of the respective elevation 4, 4', 4".

[0034] Two such fibre cast nub mats 2, 3 are made - as shown in Fig. 2 as an example - to form a component 1 according to the invention. The second fiber-cast nub mat 3 has in the Fig. 2 to 6 and in the description the reference number 3, but is identical to the fibre cast knob mat 2 of the Fig. 1a, 1b However, all reference symbols of the second fibre cast dimple mat 3 relating to the elevations, grooves and the upper side are increased by the value "1" compared to the reference symbols of the Fig. 1a and 1b . For reasons of clarity, the Fig. 2 to 6Reference symbols are sometimes omitted. However, the illustrations correspond to the Fig. 2 to 6 partly the previous figures, so that reference is made to the respective figure description of the previous figure.

[0035] In Fig. 2 a first fiber dimple mat 2 is connected to a second fiber dimple mat 3 in such a way that the first fiber dimple mat 2 is placed on the second fiber dimple mat 3, wherein the upper sides 10 of the elevations 4, 4', 4" of the first fiber dimple mat 2 and the upper sides 11 of the elevations 5, 5', 5" of the second fiber dimple mat 3 face each other and are aligned. In the exemplary embodiment shown, the top surfaces of the truncated pyramids of the respective fiber dimple mat 2, 3 are each aligned. The first fiber dimple mat 2 and the second fiber dimple mat 3 are glued to one another at the upper sides 10, 11 (i.e. the top surfaces).

[0036] The fiber-cast dimpled mats 2, 3 each have grooves 6, 6', 6"; 7, 7', 7"; 8, 8', 8"; 9, 9', 9". A groove 7; 7'; 7" of the first fiber-cast dimpled mat 2 forms a channel 12, 12', 12" with a groove 8; 8'; 8" of the second fiber-cast dimpled mat 3. Therefore, the embodiment of the Fig. 2 three channels 12, 12', 12", each with associated grooves 7, 7`, 7"; 8, 8', 8". Winding tubes 16 are inserted into the channels 12, 12', 12". The reed-like grasses 15 are inserted into the winding tubes 16 for stiffening purposes (shown only in channel 12 for reasons of clarity; winding tubes 16 with reed-like grasses 15 are also provided in the channels 12', 12"). However, it is also possible for the reed-like grasses 15 to be inserted directly, i.e. without winding tubes 16, into the channels 12, 12', 12".

[0037] Such an embodiment, in which the reed-like grasses 15 are inserted directly, ie without winding tubes 16, into the channels 12, 12', 12", is shown in the Fig. 3 shown, in which the first fiber-cast knobbed mat forms 2 grooves 6, 6`, 6"; 7, 7', 7` and the second fiber-cast knobbed mat forms 3 grooves 8, 8', 8", 8‴; 9, 9', 9". The reed-like grasses 15 are inserted into the grooves 7, 7', 7"; 8, 8', 8" (for reasons of clarity, the reed-like grasses 15 are only shown in the grooves 7, 8; reed-like grasses 15 are also provided in the grooves 8', 8"; 7, 7').

[0038] In the embodiment of the Fig. 3The first fiber-cast dimpled mat 2 and the second fiber-cast dimpled mat 3 are connected to each other via an intermediate layer 22. The intermediate layer 22 is glued to the upper sides 10, 11 of the respective elevations 4, 4', 4"; 5, 5', 5". The intermediate layer 22 consists of the same material as the fiber-cast dimpled mats 2, 3, namely fiber-cast. Due to the intermediate layer 22, the channels 12, 12', 12" are missing in the illustrated embodiment as in Fig. 2 .

[0039] In Fig. 4 An embodiment of a structural element 1 is shown, which has two further fiber-cast dimpled mats 2`, 3' as defined above. The two further fiber-cast dimpled mats 2`, 3' are glued to the first fiber-cast dimpled mats 2, 3 and thus form a quadruple layer of fiber-cast dimpled mats 2, 2', 3, 3`. The embodiment of the Fig. 4 consists of two components 1 according to Fig. 2together, whereby the coiled tubes 16 were omitted. The reed-like grasses 15 are inserted directly into the channels. This makes it possible to insert reed-like grasses 15 crossing at 90°, further increasing stability. For reasons of clarity, the depiction of all reed-like grasses 15 in the channels 12", 12', or in the rear rows, was omitted here.

[0040] In the examples of Fig. 5 and the Fig. 6 are modified embodiments of the Fig. 2 and the Fig. 4 shown. In Fig. 5 is the embodiment of the Fig. 2 with two additional plasterboards 25. In this way, a finished wall can be formed. Of course, it would also be conceivable that the embodiment of the Fig. 4 with two plasterboards 25 to increase the stability of the finished wall. Of course, it would also be conceivable that the embodiment of the Fig. 4 with two plasterboards 25 to increase the stability of the finished wall. It would also be conceivable if the examples of the Fig. 2 or 4 are provided with only one additional plasterboard 25, especially if the rear side is to be clad differently. In this way, a prefabricated wall can be created.

[0041] The example of Fig. 6 corresponds to the example of the Fig. 4 with a flowing screed plate 26, whereby a floor element is formed.

[0042] The reed-like grasses 15 are from the group consisting of Miscanthus × giganteus, Phragmites australis (common reed), Arundo donax (spine reed) or mixtures thereof selected. Particularly preferred are the reed-type grasses 15 Miscanthus × giganteus, because this material is the most stable.

Claims

1. Structural element (1) comprising at least two fibre cast nub mats (2, 3), wherein the fibre cast nub mats (2, 3) have several elevations (4, 4', 4"; 5, 5', 5"), wherein the elevations (4, 4', 4"; 5, 5', 5") are arranged in a checkerboard pattern in horizontal rows and vertical rows, wherein grooves (6, 6', 6"; 7, 7', 7", 8, 8', 8", 8‴; 9, 9', 9") are formed between the projections (4, 4', 4"; 5, 5', 5"), wherein the first fibre casting nub mat (2) is applied to the second fibre casting nub mat (3) in such a way that the upper sides (10) of the elevations (4, 4', 4") of the first fibre casting nub mat (2) and the upper sides (11) of the elevations (5, 5', 5") of the second fibre casting nub mat (3) face one another and are brought into alignment, wherein the first fibre cast nubbed mat (2) and the second fibre cast nubbed mat (3) are joined together, characterised in that reed-like grasses (15) are introduced into the channels (6, 6', 6"; 7, 7', 7", 8, 8', 8", 8‴; 9, 9', 9").

2. Structural element according to claim 1, characterised in that the first fibre cast nubbed mat (2) and the second fibre cast nubbed mat (3) are connected to one another via an intermediate layer (22), the intermediate layer (22) being connected, preferably bonded, to the upper sides (10, 11) of the elevations (4, 4', 4"; 5, 5', 5") in each case.

3. Structural element according to claim 1, characterised in that the channels (6, 6', 6"; 7, 7', 7") of the first fibre casting nub mat (2) and the channels (8, 8', 8"; 9, 9', 9") of the second fibre cast nub mat (3) form channels (12, 12', 12"), wherein the reed-like grasses (15) are introduced into the channels (12, 12', 12") formed by the channels (6, 6', 6"; 7, 7', 7", 8, 8', 8", 8‴; 9, 9', 9").

4. Structural element according to claim 3, characterised in that the reed-like grasses (15) are inserted into a winding tube (16), the winding tube (16) with the reed-like grasses (15) being inserted into the channels (12, 12', 12").

5. Structural element according to claim 4, characterised in that the winding tube (16) is made of cardboard or cast fibre material.

6. Structural element according to one of claims 1 to 5, characterised in that the reed-like grasses (15) are selected from the group consisting of Miscanthus × giganteus, Phragmites australis (reed), Arundo donax (pile reed) or mixtures thereof, particularly preferably consisting of Miscanthus × giganteus.

7. Structural element according to one of claims 1 to 6, characterised in that the elevations (4, 4', 4"; 5, 5', 5") have the shape of a square regular truncated pyramid.

8. . Structural element according to one of claims 1 to 7, characterised in that the first fibre cast nubbed mat (2) and the second fibre cast nubbed mat (3) are connected, preferably glued, to one another on the upper sides (10, 11) of the elevations (4, 4', 4"; 5, 5', 5").

9. Structural element according to one of claims 1 to 8, characterised in that the fibre cast nub mats (2, 3) comprise cellulose.

10. Structural element according to one of claims 1 to 9, characterised in that additional tubes are inserted in the grooves (6, 6', 6"; 7, 7', 7", 8, 8', 8", 8‴; 9, 9', 9") between the elevations (4, 4', 4"; 5, 5', 5").

11. Structural according to one of claims 1 to 10, characterised in that the fibre cast nub mats (2, 3) comprise graphite, preferably 3 to 6% by weight relative to the fibre cast material,12. Structural according to one of claims 1 to 11, characterised in that the fibre cast nubbed mat mats (2, 3) have a graphite coating.

13. Structural element according to any one of claims 1 to 12, characterised by at least two further fibre cast nub mats (2, 3) as defined above, wherein the two further fibre cast nub mats (2', 3') are connected, preferably bonded, to the first fibre cast nub mats (2, 3).

14. Structural element according to one of claims 1 to 13, characterised in that a plaster base plate (25) is applied to at least one fibre cast nubbed mat (2, 3).

15. Structural element according to one of claims 1 to 14, characterised in that a flowing screed plate (26) is applied to at least one fibre casting nub mat.