Flat panel and method for producing such a panel

Description

[0001] The invention relates to a planar panel for forming a wall of a building, which comprises a wall body formed from a cured rigid foam and a reinforcement arranged within the cured rigid foam and having at least one reinforcement formed entirely or at least partially from a filament yarn textile, as well as a method for producing such a panel having the features of the preamble of claim 12.

[0002] Building walls are known in various forms from the state of the art. These can be formed, for example, by stacking and joining several bricks. Walls can also be formed from poured and cured concrete. Furthermore, flat wooden wall panels are known that form a wall and can be joined together.

[0003] To form a housing wall that complies with the thermal conduction regulations, an insulating layer must be attached to the wall.

[0004] In the case of walls, especially wall panels, from the state of the art, the provision of a finished wall for a building during assembly consists of a large number of steps, which makes the installation time-consuming and costly.

[0005] Generic panels are known from US 2022 / 205242 A1, FR 2 175 669 A2, EP 0 967 340 A2 and DE 100 50 624 A1.

[0006] An object of an embodiment of the invention is to propose a planar panel for forming a wall of a housing and a method for producing such a panel, with which a wall of a building can be assembled in a more time-efficient manner.

[0007] This object is achieved in a planar panel for forming a wall of a building as mentioned at the outset by at least one continuous recess in the wall body extending in the thickness direction of the wall body and at least one frame-like reinforcement unit which is arranged in the wall body adjacent to the recess and which is designed to extend entirely or at least partially around the recess.

[0008] Because the flat panel is made of cured rigid foam and contains reinforcement within the cured rigid foam, the panel's load-bearing capacity and thermal insulation can be realized in a single component. This allows for time-efficient assembly to form a building wall.

[0009] By using a cured rigid foam and reinforcement within the rigid foam, dimensions of up to 3.3 m in height, 12 m in length, and 0.22 m in thickness can be achieved. Depending on the rigid foam, the panel can achieve a thermal conductivity class of 023.

[0010] By means of the at least one continuous recess in the wall body extending in the thickness direction of the wall body and by means of the at least one frame-like reinforcement unit which is arranged in the wall body adjacent to the recess and which is designed to encircle the recess in its entirety or at least in sections, the accessibility of an interior space enclosed by the wall can be ensured and / or the incidence of sunlight into the interior space surrounded by the wall is made possible.

[0011] By providing recesses extending in the thickness direction of the wall body, windows, doors, and access passages to additional floors can be incorporated into the panel. By providing a reinforcement unit located adjacent to the recess in the wall body, the areas of the wall body where the doors, windows, or openings are located are strengthened. This improves the load absorption by the wall body.

[0012] The panel may comprise a wall panel, ceiling panel, floor panel and / or roof panel.

[0013] In this case, a wall is understood to be a side wall, a floor, a ceiling or a roof element. If the wall includes a ceiling on one floor, this ceiling can simultaneously form a floor on the next floor.

[0014] Since the reinforcement is formed entirely or at least in sections from a filament yarn textile, it can be easily arranged in sections of the panel that are difficult to access and in which, in particular, no planar reinforcement element can be arranged.

[0015] Since the reinforcement comprises a filament yarn textile mat or a filament yarn textile grid, the reinforcement can be quickly provided over a large section of the panel, especially the wall body.

[0016] The panel makes it possible to retrofit existing buildings by attaching it to existing walls. This can improve the insulation of the wall. However, a wall can also be formed by just one panel. The panel can run in a vertical plane, encompassing an exterior or interior wall, or in a horizontal plane, encompassing a floor and / or ceiling.

[0017] In one embodiment, it proves to be advantageous if the continuous recess extending in the thickness direction of the wall body is completely surrounded by the wall body or if the continuous recess extending in the thickness direction of the wall body is accessible from the outside at least on one side in the longitudinal direction and / or in the height direction.

[0018] This allows for panel designs in which the recess is completely surrounded by the wall body, i.e., the recess is completely framed by the wall body, as well as designs in which the recess is accessible from the outside on at least one side. On these sides, the recess is then not limited by the wall body.

[0019] If the recess is entirely framed by the wall body, it proves to be advantageous if the wall body, which entirely surrounds the continuous recess extending in the direction of thickness, has an extension of at least 5 cm, in particular of at least 10 cm, at its narrowest point between the recess and the outer edge.

[0020] This makes it easier to pre-assemble a panel that encompasses doors and windows.

[0021] The reinforcement unit can, in principle, be designed in any desired manner. It proves advantageous if the reinforcement unit comprises at least one reinforcement element comprising a fibrous reinforcement element or a rod-shaped reinforcement element and / or if at least one of the at least one reinforcement element is planar and comprises a filament yarn textile mat or filament yarn textile grid comprising a plurality of fibrous reinforcement elements and / or a plurality of rod-shaped reinforcement elements.

[0022] In such cases, the same or similar elements can be used as when forming the reinforcement.

[0023] As a result, in one embodiment of the panel, it is provided that the filament yarn textile of the reinforcement element and / or of the reinforcing element is formed from basalt and forms a basalt fiber textile and / or that the cured rigid foam comprises a polyisocyanurate rigid foam (PIR) or a polyurethane foam (PUR).

[0024] By choosing PIR or PUR, a material of the thermal conduction assembly 023 is provided, which in combination with the reinforcement can simultaneously form a wall.

[0025] In principle, it is conceivable for the reinforcement to comprise only a single reinforcing element. This also applies to the strengthening unit, which may comprise only a single reinforcing element. The stability and load-bearing capacity of the panel can be further increased if the reinforcement comprises at least two reinforcing elements and the reinforcement comprises at least one spacer by which two of the at least two reinforcing elements are spaced apart from one another without contact, in particular as viewed in the longitudinal direction, height direction, or thickness direction of the wall body, and / or if the reinforcement unit comprises at least two reinforcing elements and at least one spacer by which two of the at least two reinforcing elements are spaced apart from one another without contact, in particular as viewed in the longitudinal direction, height direction, or thickness direction of the wall body.

[0026] In order to improve the accommodation of further elements, for example doors and windows, the panel can comprise at least one frame unit which is fixed in a planar manner against the edge of at least one of the at least one recess in the wall body and which surrounds the recess in a frame-like manner in its entirety or at least in sections.

[0027] The frame unit can be made stable and lightweight if the frame unit comprises at least one plate-like frame element comprising a cement-bonded chipboard.

[0028] The cement-bonded particleboard may comprise a board-shaped wood-based material formed from wooden rods or a plant material such as hemp or flax. A mineral binder, such as cement, is also added.

[0029] The plate-like frame element can be of any thickness. It is advantageous if the frame element is at least 2 cm thick, in particular at least 2.2 cm thick.

[0030] In principle, it is conceivable that the panel for forming the wall is provided with only the recesses for the wall body and the reinforcement. To simplify final assembly and reduce the assembly time for the final formation of the wall, embodiments of the panel comprise at least one door element and / or at least one window element that is fixed in the at least one recess.

[0031] The door element and / or the window element can then be mounted on the frame unit.

[0032] Furthermore, a preferred embodiment of the panel includes at least one fire barrier element that forms an outer edge of the panel and is fixed to the wall body in a planar manner. The fire barrier element and the wall body can have the same thickness. In this case, the fire barrier element continues the wall body on at least one side. The fire barrier element can have a thickness of at least 0.20 m, in particular of at least 0.22 m.

[0033] By providing the fire barrier element, the pre-assembled panel meets fire protection regulations.

[0034] The fire barrier element may comprise a mineral fire barrier. In this case, the fire barrier element may comprise mineral wool, aerated concrete, perlite, or foam glass.

[0035] In principle, it is conceivable that the individual components, such as the frame unit, door element, window element, and / or fire barrier element, are joined after the rigid foam forming the wall body has cured. However, it is also conceivable that the fire barrier element, in particular, is joined to the fire body by arranging the fluid rigid foam on the fire barrier element and allowing it to cure in this arrangement.

[0036] The same applies to frame elements, door elements and window elements.

[0037] Furthermore, the object is achieved by a method for producing a panel with at least one of the aforementioned features, comprising the steps: a. Providing and arranging a formwork comprising several formwork elements, including arranging recess formwork elements to form the at least one recess; b. Arranging the reinforcement within the formwork, including arranging reinforcing means of the reinforcement unit entirely or at least partially around the recess formwork elements; c. Closing the formwork d. Inserting or filling the rigid foam forming the wall body into the formwork; and e. Curing the system of rigid foam and reinforcement;

[0038] Step a. involves joining the essential parts of the formwork elements together, leaving access for the placement of the reinforcement within the formwork. This access is then sealed in step c. in such a way that the rigid foam forming the wall body can be inserted or filled into the formwork. The recesses in the wall body ensure a material-free space within the wall body through the appropriate design of the formwork elements.

[0039] In addition, the reinforcement means of the reinforcement unit are arranged in the wall body around these recess formwork elements.

[0040] Finally, the following further procedural steps may be provided: a. Arranging at least one fire barrier element in the formwork at least before the rigid foam is inserted or filled into the formwork; and / or b. Arranging at least one frame element of the frame unit in the at least one recess of the wall body after the rigid foam has hardened; and / or c. Arranging at least one door element and / or at least one window element in the at least one recess of the wall body after the frame element of the frame unit has been arranged in the recess of the wall body.

[0041] Further features, details and advantages of the invention emerge from the appended patent claims, from the drawings and the following description of a preferred embodiment of the panel and the method.

[0042] The drawing shows: Figure 1: A perspective front view with exploded components of a panel according to the invention; Figure 2: A schematic flow diagram of an embodiment of the method according to the invention.

[0043] Figure 1 shows a panel, generally designated by reference number 2, which forms a wall of a building (in Figure 1 not explicitly shown).

[0044] The planar panel 2 comprises a wall body 4, which is made of a hardened rigid foam. A reinforcement 6 is arranged in the wall body 4, which in the case of the Figure 1 shown embodiment comprises a plurality of reinforcement means 8. The reinforcement means 8 is formed entirely from a filament yarn textile, in particular a basalt fiber textile.

[0045] In the Figure 1In the embodiment shown, the reinforcement means 8 of the reinforcement 6 comprises a plurality of fibrous reinforcement elements which form a filament yarn textile mat or a filament yarn textile grid.

[0046] In the Figure 1 In the illustrated embodiment, the panel 2 comprises a fire barrier element 10, which forms an outer edge of the panel 2 and is fixed in a planar manner to the wall body 4. The fire barrier element 10 comprises a mineral fire barrier element 10.

[0047] Figure 1 shows an embodiment of the planar panel 2, with the two recesses 12, which are formed to extend continuously in the thickness direction of the wall body 4 and are completely surrounded by the wall body 4.

[0048] At each of the recesses 12, the panel 2 comprises a reinforcement unit 14, which comprises at least one reinforcement means 16 formed by fibrous reinforcement elements and / or rod-shaped reinforcement elements. The reinforcement elements also comprise a filament yarn textile. The reinforcement unit 14 is arranged in the wall body (4). In this embodiment, the reinforcement unit completely surrounds the recess 12 in its circumferential direction.

[0049] In addition, a frame unit 18 is arranged in each of the recesses 12 of the panel 2, which comprises at least one plate-shaped frame element 20.

[0050] In the Figure 1 In the embodiment shown, a door element 22 is arranged in one of the two recesses 12 and a window element 24 is arranged in the other recess 12.

[0051] Figure 2 shows a schematic flow diagram. Using the representation according to Figure 1The method is described below: In a first step 100, several formwork elements are provided and arranged to form a formwork. Step 100 includes arranging recess formwork elements to form the at least one recess 12.

[0052] In a subsequent step 101, the reinforcement 6 is arranged within the formwork. Step 101 includes arranging reinforcing means 16 of the reinforcement unit 14 entirely or at least partially around the recess formwork elements.

[0053] In a subsequent step 102, the formwork is closed.

[0054] Thereafter, in a step 103, the rigid foam forming the wall body 4 is inserted or filled into the formwork.

[0055] In a final step 104, the system of rigid foam and reinforcement 6 is cured.

[0056] The features of the invention disclosed in the above description, in the claims and in the drawings can be essential both individually and in any combination in the realization of the invention in its various embodiments within the scope of the following claims. List of reference symbols

[0057] 2Panel 4Wall body 6Reinforcement 8Reinforcement element 10Fire barrier element 12Recess 14Reinforcement unit 16Reinforcement element 18Frame unit 20Frame element 22Door element 24Window element 100-104Procedure steps

Claims

1. A flat panel (2) for forming a wall of a building, comprising a wall body (4) formed of a cured rigid foam and a reinforcement (6) arranged within the cured rigid foam and having at least one reinforcement means (8) formed in whole or at least in part of a filament yarn textile, characterised by at least one continuous recess (12) in the wall body (4) extending in the thickness direction of the wall body (4) and by at least one frame-like strengthening unit (14) which is arranged in the wall body (4) adjacent to the recess (12) and which is formed in its entirety or at least in sections around the recess (12).

2. Panel (2) according to claim 1, characterised in that at least one of the at least one reinforcing means (8) comprises a fibre-like or rod-shaped reinforcing element and / or in that at least one of the at least one reinforcing means (8) is designed to be flat and comprises a filament yarn-textile mat or filament yarn-textile grid having a plurality of fibre-like and / or a plurality of rod-shaped reinforcing elements.

3. Panel (2) according to claim 1 or 2, characterised in that the through recess (12) extending in the thickness direction of the wall body (4) is completely surrounded by the wall body (4) or in that the through recess (12) extending in the thickness direction of the wall body (4) is accessible from the outside at least on one side in the longitudinal direction and or in the height direction of the wall body.

4. Panel (2) according to claim 3, characterised in that the wall body (4), which completely surrounds the continuous recess (12) extending in the thickness direction, has an extension of at least 5 cm, in particular at least 10 cm, at its narrowest point between the recess (12) and the outer edge.

5. Panel (2), according to one of the preceding claims, characterised in that the strengthening unit (14) comprises at least one strengthening means (16) which comprises a fibre-like or rod-shaped strengthening element and / or in that at least one of the at least one strengthening means (16) is of flat design and comprises a filament yarn-textile mat or filament yarn-textile grid having a plurality of fibre-like and / or a plurality of rod-shaped strengthening elements.

6. Panel (2) according to one of the preceding claims 2 to 5, characterised in that the filament yarn textile of the reinforcing element and / or the strengthening element is formed from basalt and forms a basalt fibre textile and / or in that the cured rigid foam comprises a polyisocyanurate rigid foam (PIR) or a polyurethane foam (PUR).

7. Panel (2) according to one of the preceding claims, characterised in that the reinforcement (6) comprises at least two reinforcement means (8) and the reinforcement (6) comprises at least one spacer by which two of the at least two reinforcing means (8) are spaced apart from one another without contact, in particular as viewed in the longitudinal direction, height direction or thickness direction of the wall body (4), and / or in that the strengthening unit (14) comprises at least two strengthening means (16) and at least one spacer, by which two of the at least two strengthening means (16) are spaced apart from one another without contact, in particular when viewed in the longitudinal direction, height direction or thickness direction of the wall body (4).

8. Panel (2) according to one of the preceding claims, characterised by at least one frame unit (18), which is fixed in a flat manner in contact with the edge of at least one of the at least one recess (12) in the wall body (4) and which surrounds the recess (12) in a frame-like manner in its entirety or at least in sections.

9. Panel (2) according to claim 8, characterised in that the frame unit (18) comprises at least one plate-like frame element (20) which comprises a cement-bonded particle board.

10. Panel (2) according to one of the preceding claims, characterised by at least one door element (22) and / or by at least one window element (24), which is fixed in the at least one recess (12).

11. Panel (2) according to one of the preceding claims, characterised by at least one fire barrier element (10) which forms an outer edge of the panel (2) and which is fixed in surface contact with the wall body (4).

12. A method of manufacturing a panel (2) according to any one of claims 1 to 11, comprising the steps: a. Step 100: Providing and arranging a formwork comprising a plurality of formwork elements, including arranging recess formwork elements to form the at least one recess (12); b. Step 101: Arrangement of the reinforcement (6) within the formwork, including arrangement of strengthening means (16) of the strengthening unit (14) in its entirety or at least in sections around the recess formwork elements; c. Step 102: Closing the formwork; d. Step 103: Pouring or filling the rigid foam forming the wall body (4) into the formwork; and e. Step 104: Curing of the rigid foam and reinforcement system (6).

13. Method according to claim 12, characterised by the step: a. Arrangement of at least one fire barrier element (10) in the formwork at least before the rigid foam is poured or filled into the formwork; and / or b. Arrangement of at least one frame element (20) of the frame unit (18) in the at least one recess (12) of the wall body (4) after curing of the rigid foam; and / or c. Arrangement of at least one door element (22) and / or at least one window element (24) in the at least one recess (12) of the wall body (4) after the frame element (20) of the frame unit (18) has been arranged in the recess (12) of the wall body (4).