Structural element, construction system, and method for producing a structural element

Abstract

The invention relates to a prefabricated structural element (1) for an outer wall, a ceiling and / or a floor of a building, comprising: - a first cover slab (2) and a second cover slab (3); - a self-supporting frame structure (4) which is made at least in part of a fiber-reinforced plastic and to which the first cover slab (2) and a second cover slab (3) are secured in such a way that these form an air-tight cavity (5) together with the frame structure (4), the cavity (5) being filled with an insulating material (6) in a vacuum environment; and - a device for generating a vacuum and / or maintaining the vacuum in the cavity (5), comprising a valve (7) which is accessible from the outside.

Description

[0001] Vacoframe GmbH

[0002] Component, construction system and method for manufacturing a component

[0003] The invention relates to a prefabricated, preferably self-supporting, building element for a modular construction system for the production of a building wall or ceiling. Furthermore, the invention relates to a modular construction system for the production of a single- or multi-story building with at least one building element according to the invention. In addition, a method for producing a building element according to the invention is proposed.

[0004] The preferred application of the invention is the construction of single- or multi-story buildings using modular construction, i.e., using prefabricated building elements which ideally only need to be aligned, i.e., erected or placed, on the construction site to produce a building wall or ceiling.

[0005] The proposed building element can, in particular, be a load-bearing, prefabricated element for constructing a building wall or ceiling, so that no additional structurally effective elements are required for load transfer. The building element can therefore itself form a building wall or ceiling.

[0006] The term "building ceiling" is to be understood in this context as also including a floor or a floor slab, without this being explicitly mentioned in detail.

[0007] State of the art

[0008] Modular building systems shorten the on-site construction phase. The higher the degree of prefabrication of the building components used, the faster and more cost-effectively a building can be erected. Prefabrication also shifts the production of building walls or ceilings to an industrial or factory hall where consistent conditions prevail or can be created, allowing for better control of the individual production processes. Consequently, the quality of prefabricated building components is generally very high.

[0009] A well-known modular construction method is, for example, timber frame construction. This method utilizes building elements in the form of large-area panels, which feature an internal timber frame structure consisting of posts and beams and at least one sheathing layer. The posts, beams, and sheathing layer constitute the load-bearing structure, with the sheathing layer primarily serving to stiffen the frame. Insulation is typically placed between the posts and beams for sound and thermal insulation. Aesthetically pleasing surfaces can be created using additional sheathing layers on both sides, while also fulfilling all other building physics requirements for the element. If required, doors and / or windows can be pre-integrated into the element at the factory, so that after on-site erection, it forms a finished wall or ceiling.

[0010] Current thermal insulation requirements for new buildings are leading to insulation thicknesses of 500 mm and more. This poses major challenges for the construction industry. For timber frame construction, for example, this means that the insulation thickness significantly exceeds the structurally required thickness, making the construction method uneconomical.

[0011] To meet the ever-increasing demands for thermal insulation, new insulating materials and technologies, such as vacuum insulation, have been developed. The physical principle of vacuum insulation is based on the understanding that in a vacuum, no air movement, and therefore no heat transfer by convection, can occur. By creating a vacuum, insulating elements, known as vacuum insulation panels (VIPs), can be produced that offer high insulation performance with minimal thickness. However, the production of vacuum insulation panels is more complex and expensive than that of conventional insulating panels, thus limiting their practical application.

[0012] In the production of a vacuum insulation panel, the insulating material, often a loose-fill insulation material such as pyrogenic silica, is encased in multiple layers of airtight foil. The panel's strength and rigidity are then derived from the vacuum and the resulting pressure on the foil. This foil must be highly robust, as any damage would cause the vacuum to be lost and thus compromise the panel's insulating performance. For this reason, vacuum insulation panels cannot be cut to size. This means they require meticulous attention during both the planning and execution phases.

[0013] Based on the aforementioned prior art, the present invention aims to provide a building element for constructing a building wall or ceiling that is self-supporting, ideally load-bearing, and exhibits the highest possible degree of prefabrication in order to optimally utilize the advantages of a modular building system. Furthermore, the building element should meet the high requirements for thermal insulation in the most efficient way possible.

[0014] To solve the problem, the component with the features of claim 1 is proposed. Advantageous embodiments of the invention are described in the dependent claims. Furthermore, a modular construction system with at least one component according to the invention and a method for manufacturing a component according to the invention are specified.

[0015] Disclosure of the invention: A preferably self-supporting, prefabricated building element for a modular building system for the production of a building wall and / or ceiling is proposed, comprising a first cover plate and a second cover plate, a frame structure arranged between the cover plates which, together with the cover plates, airtightly encloses a cavity, an insulating material received in the cavity under vacuum formation, and a device for vacuuming and / or maintaining the vacuum in the cavity, comprising a valve accessible from the outside.

[0016] The proposed component forms a type of vacuum insulation panel, in which the vacuum is not created between two flexible films, but rather between two rigid cover plates. These, together with the intermediate frame structure, simultaneously form a load-bearing structure that eliminates the need for additional structural elements when constructing a building wall or ceiling. The proposed self-supporting, prefabricated component is preferably also load-bearing. This means that the proposed component itself is structurally effective and thus suitable for load transfer. This significantly simplifies the construction of a building wall or ceiling.

[0017] Therefore, the cover plates and the frame structure are preferably firmly connected to each other and together form a load-bearing structure.

[0018] The proposed building element is also characterized by its simple design. Furthermore, it can be completely prefabricated, so that on the construction site it only needs to be aligned, for example, erected or placed, to create a building wall or ceiling. The degree of prefabrication can be increased even further if the building element is used in the factory to produce room modules, which on the construction site only need to be arranged side by side and / or on top of each other and connected to form a building.

[0019] By utilizing vacuum insulation technology, the proposed building element also meets the stringent requirements for thermal insulation. In particular, efficient insulation can be achieved with minimal element thickness. Since the proposed building element is equipped with a vacuuming and / or vacuum maintenance system, efficient insulation can be guaranteed throughout the element's entire service life. The system's externally accessible valve allows for the connection of a vacuum pump, even after the element has been straightened, to regulate the pressure or vacuum within the cavity.

[0020] The valve is preferably integrated into a cover plate of the building element. This arrangement ensures that the valve remains accessible even after the building element has been erected, i.e., after the construction of the building wall or ceiling. Integration can be achieved, in particular, with the aid of a sleeve penetrating the cover plate, for example, a flanged sleeve, into which the valve is then inserted, preferably screwed or pressed. The sleeve thus facilitates the integration of the valve into the building element. When using a flanged sleeve, it can be inserted into the cover plate in such a way that its flange rests against the outside of the cover plate, thereby creating an airtight seal. Alternatively or additionally, a sealing element can be arranged between the flanged sleeve and the cover plate.

[0021] According to a preferred embodiment of the invention, the device for vacuuming and / or maintaining the vacuum in the cavity comprises a hose and / or a tube. A connection between the valve and the cavity can be established via the hose and / or the tube. The valve can thus be positioned as desired, allowing, for example, an easily accessible position to be chosen. The hose and / or the tube is preferably perforated in at least one section. That is, the outer layer of the hose and / or tube is perforated with holes in at least one section. Air can then be drawn from the cavity through these holes when the at least one perforated section is positioned within the cavity.

[0022] To prevent solids from entering the hose and / or pipe, and thus the valve, during air intake, a further development of the invention proposes that the hose and / or pipe be surrounded by a filter material, at least in the area of ​​the holes or perforations. This is particularly advantageous if a loose-fill insulating material is contained within the cavity. The filter material then prevents particles of the insulating material from entering the hose and / or pipe, as well as the valve connected to the cavity via the hose and / or pipe. The filter material preferably meets the requirements of filter class F4 according to EN 779 or higher.

[0023] According to a further preferred embodiment of the invention, the valve is connected to the pipe via the hose. The pipe can then be arranged entirely within the cavity. Advantageously, the pipe is perforated along its entire length and extends substantially over the entire length or width of the cavity. This allows for a uniform intake of air from the cavity to create the vacuum. In this case, the hose is not perforated. A filter material surrounding the hose is therefore also unnecessary. The cavity can also accommodate several pipes, which are connected to each other and / or to the valve via at least one hose.

[0024] Preferably, the frame construction of the proposed component comprises profiles that form a circumferential frame enclosing the cavity. The frame thus forms the lateral boundary of the cavity. To ensure an airtight seal, the frame is connected around its entire circumference to the cover plates arranged on both sides, for example, by bonding or welding. The circumferential bonding or welding simultaneously provides a continuous seal. Furthermore, the profiles preferably have a C-, L-, I-, or T-shaped cross-section. In both C- and I-shaped cross-sections, the profiles have webs or contact surfaces on both sides for the contact and, if necessary, bonding or welding of the cover plates. In the case of bonding, the web width is preferably at least 25 mm. However, webs on both sides, and thus contact surfaces for the contact of the cover plates, can also be created using profiles with an L- or T-shaped cross-section.In this case, two L- or T-shaped profiles are arranged in a mirrored pattern and joined to form a profile with a C- or I-shaped cross-section, for example by gluing or welding. The load-bearing capacity of the frame structure can thus be increased by means of double-layered webs.

[0025] As a further development measure, it is proposed that the frame structure include at least one profile that divides the cavity into chambers. This design of the component is particularly advantageous when it has very large dimensions. The at least one dividing profile then serves to reinforce the supporting structure formed by the frame and the cover plates. Particularly large components preferably have several profiles dividing the cavity into chambers. Ideally, the spacing between the profiles is chosen so that a clear distance of 600 mm is not exceeded. The at least one profile dividing the cavity can have a C-, L-, I-, or T-shaped cross-section. An I- or T-shaped cross-section is particularly advantageous.With a T-shaped cross-section, two of these profiles can be arranged in a mirrored pattern and joined to form a profile with an I-shaped cross-section, for example by gluing or welding. The resulting double webs can also increase the load-bearing capacity of the frame structure.

[0026] The at least one profile dividing the cavity into chambers preferably has at least one opening or recess for connecting the chambers. This means that the at least one opening or recess is located in the area of ​​a central web of the profile that separates the chambers. Connecting the chambers via the at least one opening or recess is important for ensuring uniform vacuuming of the cavity. This is particularly true if the device for vacuuming and / or maintaining the vacuum comprises only one valve. If the device comprises several valves, these are preferably arranged at opposite ends of a cover plate. The at least one opening or recess of the profile dividing the cavity into chambers can also serve to accommodate the hose and / or pipe through which the valve is connected to the cavity. The hose and / or pipe can be inserted through the opening or recess.The material is guided through the recess from chamber to chamber, so that the chambers are connected via this recess and only indirectly via the opening or recess.

[0027] Preferably, only one opening or recess is provided in the at least one profile that divides the cavity into chambers. This avoids unnecessary weakening of the load-bearing cross-section of the profile. Furthermore, preferably only one recess open towards one end face of the profile is provided, thus simplifying the insertion of the hose or pipe.

[0028] Furthermore, preferably the first cover plate and / or the second cover plate and / or the frame structure are at least partially made of a fiber-reinforced plastic. The use of a fiber-reinforced plastic for the frame structure prevents the formation of thermal bridges. In addition, fiber-reinforced plastics exhibit high strength combined with low weight, thus fulfilling the static requirements placed on the frame structure. A frame made of a fiber-reinforced plastic is also resistant to moisture and does not rust. This distinguishes it from a wooden or steel frame.

[0029] The term "fiber-reinforced plastic" is used here synonymously with "fiber-reinforced polymer." This means that it also includes fiber-reinforced polymers. The use of a fiber-reinforced plastic also facilitates the formation of connections, as these can be made by adhesive bonding or welding. These connections are extremely robust and therefore durable. For example, the profiles of the frame structure can be joined together by bonding or welding. Alternatively or additionally, at least one of the cover plates can be made of a fiber-reinforced plastic and bonded or welded to the frame structure. In the case of a circumferential adhesive bonding or welding, an airtight connection can be created, which is particularly necessary for creating and maintaining the vacuum in the cavity between the frame structure and the cover plates.In a further development of the invention, it is therefore proposed that the first cover plate and / or the second cover plate is glued or welded to the frame construction.

[0030] Fiber-reinforced plastic is a composite material whose physical properties can be precisely controlled by the material composition of the matrix and the arrangement of the reinforcing fibers. In this case, the fiber-reinforced plastic preferably contains glass fibers, carbon fibers, and / or aramid fibers for reinforcement. Furthermore, the fiber-reinforced plastic preferably has a synthetic polymer binder as a matrix in which the fibers are embedded. Preferably, the matrix consists of a synthetic polymer binder based on an epoxy resin. For fire protection reasons, the matrix may contain a flame retardant.

[0031] A process known as pultrusion can be used to manufacture the frame structure from fiber-reinforced plastic. This is a highly automated process, particularly suitable for producing profiles with a constant cross-section. During pultrusion, the reinforcing fibers are gradually impregnated with resin and drawn into a heated die where the matrix polymerizes. At the end of the production line, the profile is cut to the exact length. Extruded or pultruded profiles made of fiber-reinforced plastic are significantly lighter than steel while offering the same strength. Their thermal resistance is comparable to that of an insulating material, such as mineral wool.

[0032] A process called continuous lamination can be used to manufacture cover plates from fiber-reinforced plastic. This highly automated process is particularly suitable for producing sheets. In continuous lamination, the reinforcing fibers are impregnated with a resin, then compressed to the desired thickness by rollers, which simultaneously remove any unwanted air bubbles. The material then passes through a heating zone on a conveyor belt, where the resin cures and the final sheet is formed. In this way, sheets of theoretically unlimited thickness and length can be produced. Only the width of the sheet is typically limited by the width of the production line, for example, to 3000 mm. If a greater width is required, two sheets can be placed side by side and joined together.In the connection area, the plates or individual layers of plates are preferably arranged overlapping each other, resulting in an interlocking effect. The overlap area preferably has a width of at least 25 mm, ensuring a tight and airtight connection.

[0033] In a further development of the invention, it is proposed that the first cover plate and / or the second cover plate has an external single- or multi-layered cover layer. An additional barrier function can be achieved via the cover layer, preventing the passage of air and water vapor.

[0034] Preferably, the outer layer comprises a reflective metal foil and / or a polymer foil, in particular a UV-resistant polymer foil. The reflective metal foil prevents heat loss through thermal radiation, thus further improving the thermal insulation performance of the component. Up to 95% of thermal radiation can be reflected by the metal foil. Furthermore, unlike the polymer foil, the metal foil forms a barrier to lighter gases. The reflective metal foil can be, in particular, an aluminum foil. The thickness of the reflective metal foil is preferably 5 to 100 µm. The polymer layer, if present, is preferably arranged on the reflective metal foil to protect it from mechanical damage. The polymer layer therefore primarily serves a protective function. Since the polymer foil, as an outer layer, may be exposed to sunlight, it is advantageously UV-resistant.The reflective metal foil can also be replaced by a polymer foil coated with metals, thus forming a reflective metal layer. Instead of the polymer foil, a protective lacquer can be applied to the reflective metal foil, which then takes over the protective function of the polymer foil. The lacquer is preferably also UV-resistant. Furthermore, the top layer can be a laminate of a metal and a plastic foil, which are welded together.

[0035] The insulating material incorporated into the cavity of the proposed building element is preferably pourable and / or porous. A pourable and / or porous insulating material forms cavities between and / or within the individual particles. These cavities are normally filled with air and contribute to the insulating effect of the material. However, by vacuuming the cavity containing the insulating material, the air is removed, thereby increasing the insulating effect many times over. Furthermore, the pores of the insulating material preferably have a pore size of 0.01 to 100 pm. Expanded perlite can be cited as a particular example of a pourable porous insulating material with corresponding micropores. Since the pourable and / or porous insulating material may contain moisture, it is preferably actively dried before being placed in the cavity of the building element.

[0036] As an improved measure, it is proposed that a opacifying agent, such as carbon black or graphite, and / or a desiccant be added to the insulation material. The added opacifying agent leads to a further increase in the insulating performance of the insulation material. Since moisture has a negative effect on the insulating properties of the insulation material, moisture can be removed from the insulation material by adding the desiccant. This is particularly advantageous if the moisture only penetrates the vacuum-sealed cavity after the manufacturing or straightening of the building element. Since the desiccant added to the insulation material is not renewable, the amount of desiccant added is preferably determined depending on the ambient conditions expected at the building element's installation site.

[0037] Preferably, a separating layer is arranged between the insulation material and the first and / or second cover plate. This separating layer prevents direct contact between the respective cover plate and the insulation material contained in the cavity. The separating layer is preferably air-permeable and / or compressible, for example, a woven, knitted, or nonwoven fabric. The air permeability of the separating layer is advantageous for creating the vacuum in the cavity. The compressibility of the separating layer allows it to be compressed when the cavity is closed by placing the second cover plate onto the frame structure. The compression of the separating layer, in turn, allows the insulation material placed in the cavity to be compressed and fixed in place. This is particularly advantageous when using a loose-fill insulation material.When using a pourable and porous insulation material, the compressible separating layer prevents damage to the porous insulation material during compression. Furthermore, the sound insulation values ​​of the building element are improved by the intermediate compressible separating layer.

[0038] Preferably, at least one separating layer is arranged on both sides of the insulation material inserted into the cavity. Furthermore, the separating layers are preferably air-permeable and compressible. If the cavity is divided into several chambers, several separating layers are arranged on each side of the insulation material. The arrangement of the separating layers can thus be limited to the area of ​​the insulation material, so that no separating layer is located between the frame structure and the cover panels. This allows the frame structure to be connected to the cover panels by gluing or welding.

[0039] The proposed building element can have a total thickness d of 50 to 500 mm, preferably 60 to 400 mm, and more preferably 70 to 300 mm. Since the total thickness of the building element essentially corresponds to the total thickness of the building wall or ceiling to be constructed, very thin walls or ceilings can be produced if required, requiring little space. The space gained in this way can be added to the living or usable floor area of ​​the building to be erected.

[0040] According to a preferred embodiment of the invention, the first cover plate or the second cover plate has a laterally projecting section by a dimension a. This laterally projecting section facilitates the connection of a further component which—for example, to form a building wall with an external or internal corner—is oriented perpendicular to the first component. The further component can then be butted against the projecting section so that it is laterally covered by the projecting section of the first component. The dimension a therefore preferably corresponds to the total thickness d of the component.

[0041] Furthermore, it is proposed that the building element be designed in an angled or curved shape. The angled shape also allows for the construction of a building wall with an external or internal corner. In the curved version, the building element can be used to create building walls of any shape, thus offering virtually unlimited design freedom.

[0042] Furthermore, the building element preferably has at least one window-like recess. A window or door element can be inserted into this recess to complete the building wall. The window-like recess is preferably framed in the plane of the frame construction by profiles that are designed according to the profiles of the frame construction and are airtightly connected to them, in particular by bonding or welding. This means that the profiles are preferably also made of fiber-reinforced plastic and / or have a C-, L-, I-, or T-shaped cross-section. If the building element serves to construct a building ceiling, a window-like recess can also be formed in this ceiling. The recess can then serve to accommodate a flight of stairs.

[0043] According to a preferred embodiment of the invention, a connecting profile is arranged laterally on the frame structure. This connecting profile can serve to connect another component according to the invention or any other component, including a window or door element. Such a connecting profile can therefore also be provided in the area of ​​a window-like recess in the component. Preferably, the connecting profile forms a groove, a tongue, or a stepped rebate. A correspondingly designed connecting profile can then be arranged on the component to be connected, so that a positive-locking connection in the form of a tongue and groove joint or a stepped rebate joint can be achieved. The positive-locking connection facilitates the precise positioning of a component yet to be aligned relative to a component that has already been aligned and prevents movement of the components relative to each other after alignment.In particular, the positive locking mechanism prevents an offset of the connected components perpendicular to the element plane.

[0044] Furthermore, a modular building system for constructing a single- or multi-story building, comprising at least one building element according to the invention, is proposed. The building element according to the invention forms a module of the modular building system. Advantageously, the building system comprises at least two, preferably three, four, five, or six building elements according to the invention. Several building elements according to the invention can be arranged at angles to one another, so that building walls arranged at angles to one another—with or without a ceiling—are formed. Several building elements according to the invention can also be combined to form room modules, which comprise several building walls and at least one ceiling. Several room modules, in turn, can be combined to form single- or multi-story buildings, for example, by stacking the room modules. In this way, all load-bearing components of a building can be manufactured from the building elements of the modular building system.The building elements can vary, in particular being designed differently to form, for example, an exterior wall, an interior wall, a ceiling, and / or a floor. Furthermore, individual building elements can have a recess into which a window or door is inserted. The connection of two building elements according to the invention, or room modules produced therefrom, can be achieved by gluing or welding. Two building elements according to the invention arranged in one plane can be connected, in particular, by means of interlocking connecting profiles. Alternatively or additionally, the building elements can be screwed and / or clamped together.

[0045] Furthermore, a method for manufacturing a component according to the invention is proposed. The method comprises the following steps:

[0046] Construction of a frame structure,

[0047] Placing the frame structure on a first cover plate and connecting, preferably gluing or welding, the frame structure to the cover plate, so that the cover plate and the frame structure enclose an upwardly open cavity,

[0048] Introducing a preferably pourable insulating material into the cavity, placing a second cover plate on the frame construction and connecting, preferably gluing or welding, the second cover plate to the frame construction, so that the cavity (5) is enclosed airtight on all sides,

[0049] Creating a vacuum in the cavity using a device for vacuuming and / or maintaining the vacuum, comprising an externally accessible valve integrated into the component. To seal the cavity airtight, the two cover plates can each be connected to the frame structure via a circumferential adhesive or welded joint. Adhesive bonding or welding is particularly feasible if the cover plates and the frame structure are each made of fiber-reinforced plastic. Preferably, first profiles are used to manufacture the frame structure, forming a frame enclosing the cavity and having a C-, L-, I-, or T-shaped cross-section. Second profiles can also be used to manufacture the frame structure, dividing the cavity into several chambers. These second profiles can also have a C-, L-, I-, or T-shaped cross-section.

[0050] Preferably, a pourable insulation material is used, which is poured into the cavity. Furthermore, the insulation material is preferably compacted by vibration after placement, for example on a vibrating table. After compaction, the insulation material preferably forms a substantially flush surface with the top of the frame structure, so that the second cover plate can be placed on top to close the cavity.

[0051] In a further development of the invention, it is proposed that a separating layer be placed on the first cover plate before the insulation material is introduced into the cavity, and that a further separating layer be placed on top of the insulation material after it has been introduced. The insulation material is separated from the cover plates by the separating layers and simultaneously held in place between them. This is particularly advantageous when a pourable insulation material is used.

[0052] Preferably, the loose-fill insulation material arranged between the separating layers is compressed and fixed in place by these layers. To achieve this, the loose-fill insulation material is preferably introduced into the cavity and compacted so that it is essentially flush with the frame structure. The next separating layer, subsequently placed on top of the insulation material, then extends beyond the frame structure. When the second cover plate is placed on the frame structure, it is pressed down so that it comes into contact with the frame structure. The cover plate presses the immediately adjacent separating layer into the insulation material. The pressure is distributed via the insulation material to the lower separating layer, thus fixing the insulation material in place via the separating layers.

[0053] Air-permeable and / or compressible separating layers are preferred, for example, in the form of a woven, knitted, or nonwoven fabric. The use of air-permeable separating layers ensures that no air remains between the separating layers and the cover plates when the cavity is vacuum-sealed. The use of compressible separating layers allows for particularly gentle compression of the insulation material, thus preventing damage. This is especially advantageous when using a pourable and porous insulation material that is prone to breakage under pressure.

[0054] Furthermore, the separating layers are preferably cut in such a way that they only separate the insulation material from the cover panels. This means that no separating layers are placed between the frame structure and the cover panels. This ensures that the frame structure and the cover panels can be joined, in particular by gluing or welding.

[0055] Furthermore, the cavity is preferably divided into several chambers by at least one profile of the frame structure. This enables the production of particularly large-format building elements. If the cavity is divided into several chambers, a separating layer is preferably inserted into each chamber, then the insulation material is added, and subsequently another separating layer is placed on top of the insulation material. Thus, in each chamber, the insulation material is arranged between two separating layers and fixed by these layers. No separating layers are arranged between the frame structure and the cover plates.

[0056] The invention also relates to a self-supporting prefabricated building element for a modular building system for the production of a building wall and / or ceiling, comprising a first cover plate and a second cover plate, a frame construction arranged between the cover plates which, together with the cover plates, airtightly encloses a cavity, an insulating material received in the cavity under the formation of a vacuum, and a device for vacuuming and / or maintaining the vacuum in the cavity, comprising a valve accessible from the outside.

[0057] Preferably, the cover plates and the frame structure are firmly connected to each other and together form a load-bearing structure.

[0058] Preferably, the device for vacuuming and / or maintaining the vacuum in the cavity comprises a hose and / or a tube for connecting the valve to the cavity, wherein preferably the hose and / or the tube is / are perforated in at least one section.

[0059] Preferably, the frame construction comprises profiles that form a circumferential frame surrounding the cavity, wherein the profiles preferably have a C-, L-, I- or T-shaped cross-section.

[0060] Preferably, the frame construction comprises at least one profile that divides the cavity into chambers, wherein preferably the at least one profile has a C-, L-, I- or T-shaped cross-section and / or at least one opening or recess for connecting the chambers.

[0061] Preferably, the first cover plate and / or the second cover plate and / or the frame construction is / are at least partially made of a fiber-reinforced plastic, wherein preferably the first cover plate and / or the second cover plate is glued or welded to the frame construction.

[0062] Preferably, the first cover plate and / or the second cover plate has an external single- or multi-layered cover layer, which preferably comprises a reflective metal foil and / or a polymer film, in particular a UV-resistant polymer film.

[0063] Preferably the insulating material is pourable and / or porous, with the pores preferably having a pore size of 0.01 to 100 pm.

[0064] Preferably, a separating layer is arranged between the insulating material and the first cover plate and / or the second cover plate, wherein the separating layer is preferably air-permeable and / or compressible, for example a woven fabric, knitted fabric or nonwoven fabric.

[0065] Preferably, the component has a total thickness of 50 to 500 mm, preferably 60 to 400 mm, and more preferably 70 to 300 mm.

[0066] Preferably, the first cover plate or the second cover plate has a section that projects laterally by a certain amount, preferably corresponding to the total thickness.

[0067] Preferably, the component is designed in an angled or curved shape.

[0068] Preferably, the component has at least one window-like recess.

[0069] Preferably, a connecting profile is arranged laterally on the frame construction, which preferably forms a groove, a tongue or a stepped rebate.

[0070] The invention also relates to a modular building system for the production of a single- or multi-story building, comprising at least one building element according to the invention.

[0071] Finally, the invention relates to a method for manufacturing a component according to the invention, comprising the steps

[0072] Manufacturing a frame structure, placing the frame structure on a first cover plate and connecting, preferably gluing or welding, the frame structure to the cover plate, so that the cover plate and the frame structure enclose an upwardly open cavity,

[0073] Introducing a preferably pourable insulating material into the cavity,

[0074] Placing a second cover plate on the frame structure and connecting, preferably gluing or welding, the second cover plate to the frame structure so that the cavity is enclosed airtight on all sides, creating a vacuum in the cavity using a device for vacuuming and / or maintaining the vacuum, comprising a valve integrated into the component and accessible from the outside.

[0075] Preferably, a separating layer is placed on the first cover plate before the insulation material is introduced into the cavity, and a further separating layer is placed on the insulation material after the insulation material has been introduced, preferably using air-permeable and / or compressible separating layers, for example in the form of a fabric, knitted fabric or nonwoven.

[0076] All embodiments and components of the devices described herein are preferably designed to be manufactured according to one or more of the methods described herein. Furthermore, all embodiments of the devices and all embodiments of the methods described herein can be combined with one another, preferably also independently of the specific configuration in which they are mentioned.

[0077] It is generally noted that terms like "ein" (a) and "eine" (a / an) do not necessarily mean "exactly one" or "exactly one," although this is also possible. The terms "ein" and "eine" can therefore be understood as "at least one" or "exactly one." The use of the singular preferably includes the plural presence of the components, and vice versa. It is noted that "vorzugsweise" (preferably) and "bevorzugt" (preferred) can be translated as "preferably" in English. A feature introduced by "vorzugsweise" or "bevorzugt" is purely optional, can be omitted, and does not constitute a limitation, for example, of the claims.

[0078] Preferred embodiments of the invention are explained in more detail below with reference to the accompanying drawings. These show:

[0079] Fig. 1 shows a perspective view of a component according to the invention.

[0080] Fig. 2 is an exploded view of the component of Figure 1,

[0081] Fig. 3 a) a cross-section through a component according to the invention, b) a cross-section through a cover plate of a component according to the invention, c) a top view of a frame construction of a component according to the invention and d) a further cross-section through a component according to the invention,

[0082] Fig. 4 a) an exploded view of a frame construction of a component according to the invention and b) a further exploded view of the frame construction in the area of ​​a profile connection,

[0083] Fig. 5 shows a cross-section through a component according to the invention in the area of ​​a device for vacuuming and / or maintaining a vacuum,

[0084] Fig. 6 shows a cross-section through a component according to the invention in the area of ​​a pressure sensor,

[0085] Fig. 7 a) a perspective view of a component according to the invention with a window-like recess and multi-layered cover plates, b) a top view of the cut of a first layer, c) a top view of the cut of a second layer of a multi-layered cover plate of the component and d) a perspective view of the layers before joining,

[0086] Fig. 8 a) a cross-section through an angularly designed component according to the invention and b) a perspective view of the frame construction of the angularly designed component,

[0087] Fig. 9 a) a cross-section through a curved component according to the invention and b) a perspective view of the frame construction of the curved component,

[0088] Fig. 10 a) a cross-section through two butt-jointed and connected components according to the invention and b) a cross-section of the butt-jointed and connected components,

[0089] Fig. 11 a) a cross-section through two components according to the invention arranged side by side in one plane and to be joined, and b) a cross-section through the two components after joining,

[0090] Fig. 12 a) a cross-section through two components according to the invention arranged side by side in one plane and to be joined, and b) a cross-section through the two components after joining,

[0091] Fig. 13 a) a cross-section through two components according to the invention arranged side by side in one plane and to be joined, and b) a cross-section through the two components after joining,

[0092] Fig. 14 shows a cross-section through a component according to the invention in the connection area of ​​a window element,

[0093] Fig. 15 shows a cross-section through a component according to the invention in the connection area of ​​a door element, Fig. 16 shows an exploded view of the modules of a modular building system according to the invention,

[0094] Fig. 17 shows a perspective view of the modules of Fig. 16 after they have been joined to form a room module and

[0095] Fig. 18 shows a perspective view of the room module of Fig. 17 and another room module before joining.

[0096] Detailed description of the drawings

[0097] Figure 1 shows a building element 1 according to the invention for a modular building system. In particular, a building wall or ceiling can be manufactured from the building element 1. Several building elements 1 according to the invention can form the load-bearing components of a single-story or multi-story building.

[0098] The component 1 shown in Figure 1 comprises a circumferential frame structure 4 formed from profiles 4.1, which is arranged between two cover plates 2, 3. The cover plate 3 has an overhang of dimension a on two opposite sides. The profiles 4.1 of the frame structure 4 and the two cover plates 2, 3 are each made of a fiber-reinforced plastic and are bonded or welded together. In this way, a lightweight yet robust unit is achieved, which forms the load-bearing structure of the component 1.

[0099] As can be seen in Figure 2, the frame structure comprises four additional profiles 4.2, which subdivide a cavity 5 enclosed by the profiles 4.1 into several chambers 5.1, 5.2, ..., 5.n. The profiles 4.2 further stiffen the frame structure 4, thus increasing its load-bearing capacity. The profiles 4.2 are therefore particularly advantageous for very large building elements 1. During the production of the building element 1 shown in Figure 2, insulating material 6 is placed in each chamber 5.1, 5.2, ..., 5.n. This insulating material 6 can be in the form of a mat, a board, or loose fill. For example, expanded perlite can be used as a loose-fill insulating material 6.

[0100] Separating layers 12 are arranged on both sides of the insulation material 6 to separate the insulation material 6 from the cover plates 2, 3. The separating layers 12 are air-permeable and compressible. The air permeability of the separating layers 12 ensures that no air remains between the separating layers 12 and the cover plates 2, 3 when the cavity 5 is subsequently vacuum-sealed. The compressibility of the separating layers 12 allows the insulation material 6 to be fixed in the cavity 5, particularly when using a loose-fill insulation material 6. Furthermore, the compressibility of the separating layers 12 improves the sound insulation values ​​of the building element 1.

[0101] After the insulation material 6 and the separating layers 12 have been inserted, the cavity 5 is closed. For this purpose, the remaining cover plate 2 is placed on the frame structure 4 and connected to it, for example by gluing or welding. By gluing or welding the cover plates 2 and 3 to the frame structure 4 all around, the cavity 5 can be sealed airtight. A vacuum is then created in the airtight cavity 5 using a vacuuming device.

[0102] As illustrated by way of example in Figure 5, the vacuuming device comprises an externally accessible valve 7, which in this case is connected via a hose 8 to a pipe 9 located in the cavity 5. The pipe 9 is perforated and extends—depending on the orientation of the component 1—over the entire length or width of the cavity 5 to ensure that the air is drawn in evenly during vacuuming. To prevent particles of the loose-fill insulation material 6 from being drawn in, the perforated pipe 9 is surrounded by a filter material 18. The externally accessible valve 7 is inserted, in particular screwed, into a collar 21, which is integrated into one of the two cover plates 2, 3 (in this case, the cover plate 2). The collar 21 facilitates the installation of the valve 7 and also enables an airtight connection of the hose 8.As a precautionary measure, a filter element 22 is inserted in the hose 8 or in the collar sleeve 21 to prevent particles of the insulation material 6, drawn in during vacuuming, from entering the valve 7 and blocking it. While the filter material 18 surrounding the pipe 9 should be at least filter class F4 according to EN 779, filter class F7 according to EN 779 is recommended for the filter element 22.

[0103] To monitor the vacuum in the cavity 5 during vacuuming, a pressure sensor 23 is preferably provided. An example of such a pressure sensor 23 can be seen in Figure 6. In this embodiment, the pressure sensor 23 is inserted, in particular screwed, into a further collar sleeve 21, which is integrated into the cover plate 2.

[0104] In the simplest embodiment of a component 1 according to the invention, it terminates laterally with the frame construction 4 or the profiles 4.1 of the frame construction 4. The cover plates 2, 3 form the surfaces or visible surfaces of the component 1 that remain visible after the component 1 has been straightened. Such an embodiment can be seen in Figure 3a). Since, in the event of a leak, not only air but also moisture can enter the cavity 5, a desiccant 19 is contained in the insulating material 6.

[0105] The cover plates 2, 3 of a component 1 according to the invention can have a single- or multi-layered cover plate 11. Figure 3b) shows an example of a multi-layered cover plate 11 comprising a reflective metal foil 11.1 and a UV-resistant polymer foil 11.2 applied thereto. Such a multi-layered cover plate 11 is particularly advantageous for the cover plate 2, 3, which, after the component 1 has been straightened, forms the outer surface of the wall and can therefore be exposed to sunlight. As already mentioned, the frame construction 4 can have different first profiles.

[0106] 4.1 and second profiles 4.2. The first profiles 4.1 then form a circumferential frame enclosing the cavity 5, and the profiles 4.2 divide the cavity 5 into several chambers 5.1, 5.2, ... 5.n (see Figure 3c)). As can be seen in Figure 3d), the first profiles 4.1 can, in particular, have a C-shaped cross-section and the second profiles 4.2 an I-shaped cross-section. To reinforce the profile cross-sections, two L-shaped profiles can also be arranged in reverse and bonded or welded together to form a C-shaped profile 4.1 (see, for example, Figures 13a) and 13b)), or two T-shaped profiles can be arranged in reverse and bonded or welded together to form an I-shaped profile 4.2 (not shown).

[0107] To manufacture the frame structure 4, profiles 4.1 and 4.2 can be glued or welded together. In order to create sufficiently large bonding surfaces in the case of gluing, preferably a flange-free end section of each profile 4.2 extends into the profile 4.1, so that this end section abuts the end face of the profile 4.1 and the flanges of both profiles 4.1

[0108] 4.2 Finish flush with the surface. In the area of ​​the tube 9, the end sections of the profiles 4.2 have a recess 10 on the end face for receiving the tube 9 (see Figures 4a) and 4b)). This allows the tube to pass through all chambers 5.1, 5.2,

[0109] . . .5.n will be led.

[0110] As exemplified in Figure 7a), a building element 1 according to the invention can have a window-like recess 13 for receiving a window or door element (not shown). This applies in particular when the building element 1 serves to form a building wall. The window-like recess 13 is surrounded by profiles 4.1 of the frame construction 4 to seal the cavity 5 airtight towards the window-like recess 13. Since the large recess weakens the building element 1, the cover plates 2, 3 are each made up of multiple layers. At the same time, the multiple layers 2.1, 2.2 are made up of multiple parts to reduce waste during the manufacture of the cover plates 2, 3. In the illustrated embodiment, the first layer 2.1 of the cover plate 2 comprises four parts 2.1.1, 2.1.2, 2.1.3, 2.1.4 (see Figure 7b)). The second layer 2.2 of the cover plate 2 comprises four parts 2.2.1, 2.2.2, 2.2.3, 2.2.4 (see Figure 7c)), where the cut varies to avoid overlapping joints between the parts (see Figure 7d)).

[0111] For multi-layered and multi-part cover plates 2, 3, the parts of a cover plate 2, 3 should always have overlapping layers 2.1, 2.2 in the connection area. Ideally, the overlap area should not be narrower than 25 mm.

[0112] Since a building typically comprises several exterior walls arranged at angles to one another, thus forming at least one exterior or interior corner, a modular building system for constructing the building can include at least one building element 1 according to the invention, which is designed at an angle or is curved. An example of an angled building element 1 is shown in Figures 8a) and 8b). An example of a curved building element 1 is shown in Figures 9a) and 9b). In the angled building element 1, the cover plates 2, 3 are butted together in the corner areas and glued or welded. As can be seen in Figure 8b), a profile 4.2 is missing in the corner areas. Instead, an angled profile 4.3 can be arranged in the corner areas – on one or both sides (see Figure 8a)).

[0113] Another possible corner formation is shown in Figures 10a) and 10b). This requires a component 1 whose outer cover plate, in this case cover plate 3, has a lateral overhang. The lateral overhang has dimension a, where dimension a corresponds to the total thickness d of the second component 1 arranged at an angle to it. The cover plate 2 of the first component 1 thus covers the side surface of the second component 1, which is formed by a profile 4.1 of the frame structure 4. The cover plates 2, 3 and frame structures 4 of the two components 1 can be fully bonded or welded together in the contact area. In the case of particularly large building walls, several components 1 can also be arranged side by side in one plane and connected to each other. The connection is preferably detachable.Exemplary embodiments are shown in Figures 11a) and 11b), 12a) and 12b), and 13a) and 13b). In the embodiment shown in Figures 11a) and 11b), connecting profiles 14 with a projecting flange section are arranged on each of the two lateral profiles 4.1 of the components 1 to be joined. These connecting profiles allow the two components 1 to be screwed and / or clamped together. In the embodiment shown in Figures 12a) and 12b), the lateral profiles 4.1 of the two components 1 are covered by connecting profiles 14 that form a stepped rebate 17, thus achieving a positive fit in the connection area. Additional external profiles 20 allow the components 1 to be screwed and / or clamped together. In the embodiment shown in Figures 13a) and 13b), the lateral profiles 4.1 are each formed by two L-shaped profiles.This allows for a greater overall thickness of the component 1. Connecting profiles 14 are arranged on the profiles 4.1, forming grooves 15 and tongues 16, thus enabling a tongue and groove connection. Additional external profiles 20 also allow the components 1 to be screwed and / or clamped together.

[0114] In the area of ​​a window-like recess 13 of a building element 1 according to the invention, for example for receiving a window or door element, a connecting profile 14 can also be arranged on the surrounding profiles 4.1 to facilitate the connection of the window or door element. Figure 14 shows an example of a connection of a window element 24 to a profile 4.1 of a building element 1 according to the invention, realized via a connecting profile 14. Figure 15 shows an example of a building element 1 according to the invention with a connecting profile 14, to which a door frame 25 with a door leaf 26 is connected.

[0115] Several identical and / or differently designed building elements 1 form a modular building system that enables the construction of a single- or multi-story building. For example, five building elements 1 according to the invention can be combined to form a room module which—as illustrated by way of example in Figures 16 and 17—has three walls and two ceilings. To enclose the room module laterally, another building element 1 or another room module can be attached (see Figure 18). In this way, all load-bearing elements of the building can be manufactured from building elements 1 according to the invention. Windows and / or doors can be provided at any desired location. Similarly, several building elements 1 according to the invention, or room modules formed therefrom, can be assembled to form a single- or multi-story building.

[0116] It is explicitly pointed out that a building element 1 according to the invention can be used not only for the construction of an exterior building wall, but also for the construction of an interior building wall. Since the requirements for an interior building wall, particularly with regard to load-bearing capacity, sound and / or thermal insulation, and other building physics requirements, are generally lower than those for an exterior building wall, the use of a building element 1 according to the invention for the construction of an interior building wall is not described in detail.

[0117] Reference symbol list

[0118] 1 component

[0119] 2 Cover plate

[0120] 2.1 first layer

[0121] 2.1.1 first part

[0122] 2.1.2 second part

[0123] 2.1.3 third part

[0124] 2.1.4 Part Four

[0125] 2.2 second layer

[0126] 2.2.1 first part

[0127] 2.2.2 second part

[0128] 2.2.3 third part

[0129] 2.2.4 Part Four

[0130] 3 Cover plate

[0131] 4 Frame construction

[0132] 4.1 Profile

[0133] 4.2 Profile

[0134] 4.3 Profile

[0135] 5 Cavity

[0136] 5.1 Chamber

[0137] 5.2 Chamber

[0138] 5th Chamber

[0139] 6 Insulation material

[0140] 7 valve

[0141] 8 hose

[0142] 9 pipe

[0143] 10 recesses

[0144] 11 Top layer

[0145] 11.1 Metal foil

[0146] 11.2 Polymer film 12 Separation layer

[0147] 13 recess

[0148] 14 Connection profile

[0149] 15 groove 16 spring

[0150] 17 stepped fold

[0151] 18 filter materials

[0152] 19 Desiccants

[0153] 20 Profile 21 Collar sleeve

[0154] 22 filter element

[0155] 23 Pressure sensor

[0156] 24 window elements

[0157] 25 Door frame 26 Door leaf

Claims

- 32 - Patent claims 1. Prefabricated building element (1) for an exterior wall, a ceiling and / or a floor of a building, comprising a first cover plate (2) and a second cover plate (3), and a self-supporting frame structure (4), which is at least partially made of a fiber-reinforced plastic, to which the first cover plate (2) and a second cover plate (3) are attached in such a way that they, together with the frame structure (4), form an airtight cavity (5) form, wherein the cavity (5) is in a vacuum environment with a insulating material (6) is filled, and a device for vacuuming and / or maintaining the vacuum in the cavity (5), comprising an externally accessible valve (7) 2. Component (1) according to claim 1, characterized in that the self-supporting frame construction (4) comprises profiles (4.1) which form a circumferential frame enclosing the cavity (5), wherein the profiles (4.1) preferably have a C-, L-, I- or T-shaped cross-section.

3. Component (1) according to one of the preceding claims, characterized in that the frame construction (4) comprises at least one profile (4.2) which is rigidly connected to the profiles (4.1) of the surrounding frame and divides the cavity into chambers (5.1, 5.2, ...5.n), wherein the profile (4.2) preferably has a C-, L-, I- or T-shaped cross-section and at least one opening or recess (10) for connecting the chambers (5.1, 5.2, ...5.n).

4. Component (1) according to one of the preceding claims, characterized in that the self-supporting frame construction (4) is such that - 33 - is such that, after the formation of a vacuum, it allows the first cover plate (2) and the second cover plate (3) to deflect and / or the insulating material (6) located in the cavity (5) to be mechanically compressed.

5. Component (1) according to one of the preceding claims, characterized in that the first cover plate (2) and / or the second cover plate (3) is / are flexible, wherein the first cover plate (2) and / or the second cover plate (3) preferably consists at least partially of fiber-reinforced plastic and / or metal.

6. Component (1) according to one of the preceding claims, characterized in that the first cover plate (2) and / or the second cover plate (3) has an external single- or multi-layer cover layer (11) which preferably comprises a reflective metal foil (11.1) and / or a polymer film (11.2), in particular a UV-resistant polymer film.

7. Component (1) according to one of the preceding claims, characterized in that the first cover plate (2) and the second cover plate (3) are bonded and / or welded to the frame construction (4).

8. Component (1) according to one of the preceding claims, characterized in that the component has a flat shape with a total thickness (d) between 30 mm and 500 mm, preferably between 30 mm and 300 mm, particularly preferably between 30 mm and 200 mm.

9. Component (1) according to claim 1, characterized in that the first cover plate (2) and / or the second cover plate (3) has a flange (21) to which an externally accessible vacuum valve (7) is attached and to which a tube (9) for distributing the vacuum into the cavity (5) is connected internally, the tube being perforated at least at one point, wherein the perforated part of the tube (9) is covered with a filter material (18), wherein the tube (9) is preferably connected to the flange (21) via a hose (8).

10. Component (1) according to one of the preceding claims, characterized in that the insulating material (6) is porous, wherein the pores preferably have a pore size between 0.01 pm and 100 pm 11. Component (1) according to one of the preceding claims, characterized in that a permanently elastic separating layer (12) is arranged over the entire surface between the insulating material (6) and the first cover plate (2) and the second cover plate (3), which is designed to compress the microporous insulating material (6) during the manufacturing process and to permanently fix it in the cavity (5), wherein the separating layer, preferably a fabric, knitted fabric and / or nonwoven fabric (12), is preferably air-permeable and / or compressible.

12. Method for manufacturing a component (1) according to claim 10, characterized in that: - the self-supporting frame structure (4) is placed on a first cover plate (2) and connected to the cover plate (2), preferably by gluing and / or welding, so that the cover plate (2) and the frame structure (4) enclose an upwardly open cavity (5). - a first permanently elastic separating layer (12) is placed on the inside of the first cover plate (2), - Insulation material (6) is placed into the cavity (5) up to the height of the top edge of the frame structure (4) and compacted by vibration, - a second permanently elastic separating layer (12) is placed on the insulation material (6), an adhesive for attaching the second cover plate (3) is applied to the frame construction (4), and - the second cover plate (3) is applied as the last layer under pressure, whereby the first separation layer (12) and the second separation layer (12) are compressed to half their original thickness during manufacturing, which simultaneously compresses the insulating material (6) and permanently fixes it in the cavity (5) of the building element (1). - Creating a vacuum in the cavity (5) using a vacuuming and / or vacuum maintenance device comprising an externally accessible component integrated into the component (1) Valve (7).

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