Reinforced rock wool, a constructional component, and manufacturing method

Abstract

In particular, the invention is a light-weight architectural block that will meet the need for a partition wall in buildings, that is placed horizontally over the vertical openings such as doors and windows, that will be used to enable continuation of walls, and will perform the function of Lintel, through its thermal insulation properties, to eliminate the issue of heat bridge, to enhance fire resistance, to reduce the weight of walls in buildings, to mitigate the risks for occupational health and safety, and to contribute to the sound insulation. It consists of a plasterboard (a) that is placed on the sides of the lintel structure to provide strength to the lintel structure, rock wool plate (b) in the center of the lintel structure that gives thermal insulation, sound insulation and fire resistance to the structure, adhesive (c) that is applied on the rock wool plate (b) to enhance the tensile strength and bending strength of rock wool plate (b), and plaster (d) that is used as an exterior layer to enhance the strength of lintel structure.

Description

[0001] REINFORCED ROCK WOOL, A CONSTRUCTIONAL COMPONENT, AND MANUFACTURING METHOD

[0002] Technical Area

[0003] The invention is a light-weight architectural block that is placed over the openings such as doors and windows in the buildings.

[0004] Specifically, the invention is a light-weight architectural block that will meet the need for a partition wall in buildings, that is placed horizontally over the vertical openings such as doors and windows, that will be used to enable continuation of walls, and will perform the function of Lintel, through its thermal insulation properties, to eliminate the issue of heat bridge, to enhance fire resistance, to reduce the weight of walls in buildings, to mitigate the risks for occupational health and safety, and to contribute to the sound insulation. The manufacturing method for this architectural block is also described.

[0005] State of the Art

[0006] Today, the need for shelter is increasing day by day with the increasing human population. Available techniques, products and methods in the construction industry are upgraded in line with the needs of the modern age.

[0007] The buildings are continuously tested by external factors and are expected to withstand disasters such as earthquakes, fires and floods. One of the major problems to be solved is the weight of the buildings.

[0008] The part designed to horizontally fill the top of the vertical openings of the buildings such as doors and windows and to bear the weight on it is called a "lintel".

[0009] This part is of extra importance during the construction phase of the building. Since it cannot be built flat with bricks like a wall, it brings about insulation, strength and safety issues.

[0010] One side of the lintels faces the inside of the building while the other faces the outside. Even if insulation is installed inside the building, if insulation is missing in these parts, heat exchange between inside and outside cannot be prevented and a thermal bridge is formed. Sometimes they need to be lifted and positioned on top of the doors and windows, with a length of up to 2.5 meters. Considering the weight of the small bricks used, apparently, it is a rather heavy block. It is not possible for one worker to lift it, and there is a high risk for occupational health and safety if it is not positioned correctly in any way or if it is dropped. A large part of lintels currently used is concrete. A lintel requires to contain extra steel / iron pipes and reinforcements to bear the load on it and provide sufficient tensile strength and bending strength. This both increases the current weight of the lintel and prolongs the manufacturing time.

[0011] Since the products used in current applications have a weight of 900 kg / m3-2200 kg / m3, they pose a serious risk for occupational health and safety in practice. In addition, its thermal insulation performance is very low. Therefore, thermal bridges are formed. Since the sound insulation of the currently used products is very low, they are insufficient for providing comfort to people.

[0012] The products currently used can be manufactured in molds due to their nature and structure. Therefore, the manufacturing time is very long.

[0013] A Turkish application (number: 2017 / 08773) for utility model refers to a lintel structure. Lightening groves are made to lighten the structure. A carrier profile is added for its strength. Use of a carrier profile and pumice or brick block does not give the desired result.

[0014] A Turkish application (number: 2015 / 08417) for patent refers to a design of cementbased lintel. However, this method is not preferred because cement-based molds are used and the molds should be allowed to dry.

[0015] The application (number: WO2012093970) for PCT describes a lintel that provides insulation, and manufacturing method for this lintel. Although this method is better than the others in insulation, the structure that should be used to expose the product, and the strength and weight of the lintel formed are not as desired.

[0016] As a result, it is deemed necessary to make an improvement of the relevant technical area because of the problems described above and the inadequacy of the existing solutions to such problems. Purpose of the Invention

[0017] Unlike the methods used for the available technique, the invention is intended to present a structure with different technical features that brings a new perspective in this field.

[0018] The purpose of the invention is to reduce the weight of the lintel that would not contain any steel / iron reinforcements.

[0019] The other purpose of the invention is to provide the tensile strength and bending strength that are required by the lintel by using a light-weight product such as rock wool.

[0020] Another purpose of the invention is to prevent formation of a thermal bridge through the lintel because of the temperature difference in the interior and exterior parts of the structure, and to provide a thermal insulation.

[0021] Another purpose of the invention is to provide a sound insulation with the insulation materials it contains.

[0022] Another purpose of the invention is to enhance the fire resistance of the lintel with plaster having higher fire resistance on the lintel.

[0023] Another purpose of the invention is to lighten the lintel in order to facilitate placement of it on the doors and windows in the buildings, and to mitigate the risks for occupational health and safety.

[0024] To achieve to purposes above, the invention consists of plasterboard, rock wool plate, adhesive and plaster.

[0025] Furthermore, to achieve to purposes above, the invention involves the following steps:

[0026] • Rock wool is cut to the desired size.

[0027] • Rock wool is covered by the adhesive.

[0028] • The adhesive (c) is compressed by means of a press with chemicals saturated by water, and as a result, tensile strength, compressive strength and bending strength of insulation member (b) are enhanced.

[0029] • The rock wool with adhesive applied is covered with plaster having higher fire resistance. Description of Figures

[0030] Figure 1 . Sectional view of rock wool lintel that is the subject of invention.

[0031] Figure 2. Sectional view of rock wool lintel that is the subject of invention.

[0032] Description of Part References a. Plasterboard b. Rock wool plate c. Adhesive d. Plaster

[0033] Detailed Description of the Invention

[0034] This detailed description provides the preferred embodiments of the invention only for a better understanding of the subject and without allowing any limiting effects.

[0035] The invention in question is lighter than the existing products, because of the materials it contains. In this way, it is much more risk-free in terms of occupational health and safety compared to existing products. Since the lintel is light-weight, it allows much faster and easier installation compared to the products that are currently used. In addition, the product, which should be used in countries located on the seismic belts, performs better in terms of both building and human safety in the event of a possible earthquake, thanks to its much lighter weight compared to the existing products.

[0036] Since the invention in question consists of components with higher thermal insulation, its thermal insulation is higher compared to the products currently used. It prevents thermal bridges. In this way, it saves more energy. It makes a substantial contribution to preventing formation of condensation, mold and deformation compared to the existing products.

[0037] Since the invention in question provides a sound insulation, it provides higher sound insulation than the currently used products, providing higher benefits for human health and comfort compared to the existing products.

[0038] The invention in question can be cut in the construction site against dimensional mismatch as compared to many products that are currently used, and even if it is cut, its tensile strength, bending strength, properties of thermal and sound insulation, and fire resistance remain the same. A number of manufacturers need to note that many of their products cannot be cut in the construction site, and they also report that available properties may be subject to problems if it is cut.

[0039] The product has A1 reaction to fire.

[0040] Since the product in question is not manufactured in a mold, the manufacturing time is much shorter than that of the current products. In this way, requirements of a construction site can be met in a much shorter time.

[0041] The lintel does not require any reinforcement to pass through, enhancing the strength and resistance, which is one of the most important features of the invention in question.

[0042] The rock wool plate (b), which provides thermal insulation, sound insulation and fireproofing, is placed as a block in the center of the product. Normally, the rock wool is an insulation material that hardly bears its own weight and has no tensile and bending strength. However, the invention in question involves using a chemical adhesive (c) and then pressing for a long time, as a result, the bonds in the rock wool gain strength and are hardened. The pressing time varies depending on the size of the lintel.

[0043] The plasterboard (a) is placed on the side surfaces of the hardened rock wool plate (b). Depending on the demand, all surfaces or two opposite surfaces can be placed on the lintel in a way to face the interior and exterior of the building. The plasterboard (a) provides strength to the building.

[0044] The formed structure is finally covered with plaster (d). This plaster can be a cement- added plaster and contains chemicals with higher fire resistance. The plaster provides strength to the lintel structure and can be easily applied without making the structure heavier.

[0045] Since heavy materials such as concrete and steel are not used in the structure, the structure remains quite light-weight compared to existing products.

[0046] Based on the requirements, the structure can be cut to different sizes and can be used as a brick for buildings.

[0047] Since the chemicals are saturated by water, the adhesive (c) is pressed for 2 to 8 hours under the temperature and pressure. Thus, pretension strength, compression strength and tensile strength of the product are enhanced so that the rock wool plate (b) can gain strength. The product that has gained strength is rigid and has higher bearing force and the insulation and strength properties are superior that the available products.

[0048] The gaps on the rock wool plate (b) are filled with chemical adhesive, bonding the system in the x, y, and z directions and providing adhesion with a significant tensile force. In this way, the system stands together as a composite.

[0049] The preferred temperature when the adhesive (c) fuses with the rock wool plate (b) and produces the composite material is between 5 and 55 degrees. Pressure values are between 50 and 500 kPa. This pressure is applied on the product for 2 to 8 hours with variable frequencies.

[0050] Since both the rock wool plate (b) in the architectural block and the plaster (d) give strength and resistance, the insulating materials can be used instead of use of concrete. Therefore, the weight is reduced. It is possible for minimum one and maximum two persons to easily lift and lower the block. In addition, it performs well above the existing products in terms of thermal and sound insulation. Weight per M3of material is 300-350 kg. It is very light-weight as compared to other products that are currently available in the market.

[0051] A regular rock wool may not provide the same effect in this structure. Therefore, there is no such use at present because the rock wool will break by the loads placed on it. The available products gain strength by passing through a profile in the center of the product. The fundamental difference is that there is a product that shows the required strength without passing any support member through the product. A soft product such as rock wool is bonded to the plasterboard (a) by a chemical adhesive (c) to form a composite material. The rock wool plate (b) in the center of the rock wool with high compressive strength and tensile strength does not require any profile and performs its function.

[0052] In general, the product can be easily transported and applied, it eliminates such factors that would endanger occupational health and safety, and at the same time, it is possible to apply the architectural block, which has sound insulation, thermal insulation and fireproofing properties, in a faster and easier way.

[0053] At the same time, the loss of time in the drying and transportation of the lintels manufactured in the construction site conditions will be prevented. Through mass production, it can be manufactured in the desired size and dimensions and trimmed in the site to obtain the desired size. It is one of the important features of the product that it can be applied quickly and practically. This invention, which eliminates the occupational health and safety risks, will also reduce the additional earthquake load to occur thanks to its light-weight.

[0054] Steel concrete and gas concrete are used as a load-bearing member in equivalent products in the market. This is the case all over the world. The main difference of the said invention is that the rock wool, which is not used as a load-bearing member but used as an insulation material, is strengthened to fulfill the role of steel and concrete and transformed into a load-bearing rock wool. In this way, while the weight of the equivalent products ranges 500 to 900 kg / m3, a load-bearing constructional component is obtained with 300-350 kg / m3.

[0055] In addition, as the product is light-weight, the transportation costs are reduced and the amount of fuel used by the vehicles while transporting the products is reduced, with decreased carbon emissions.

[0056] Another advantage of the present invention is that the strength of the product does not decrease despite the lengthening of the product. For example, this product can be used up to 2.5 meters. A product of this length is not available in the market without adding any reinforcement.

[0057] A rigid and robust load-bearing product is achieved through such processes. Based on the need for the existing lintel, this product has been developed and will be available in different areas in the future. It can act as a brick as a load-bearing wall element, and can be used in areas where thermal insulation is important, such as chimneys, by changing its dimensions.

Claims

CLAIMS1. In particular, the invention is a light-weight architectural block that will meet the need for a partition wall in buildings, that is placed horizontally over the vertical openings such as doors and windows, that will be used to enable continuation of walls, and will perform the function of Lintel, through its thermal insulation properties, to eliminate the issue of heat bridge, to enhance fire resistance, to reduce the weight of walls in buildings, to mitigate the risks for occupational health and safety, and to contribute to the sound insulation.• It can be placed on the sides of the lintel structure lento, and it contains minimum one plasterboard (a) that provides strength to lintel structure lento• It contains a rock wool plate (b) in the center of the lintel structure, which gives thermal insulation, sound insulation and fire resistance to the structure• It contains an adhesive (c) that is applied on the rock wool plate (b), enhancing the tensile strength and bending strength of rock wool plate (b).• It contains plaster (d) that is used as an exterior layer to enhance the strength of lintel structure.

2. The benefit of the architectural block referred to in Claim 1 is that rock wool plate (b) is made of the rock wool, an insulating material.

3. The invention is a method for manufacturing a light-weight architectural block that can be used in the buildings and has thermal and sound insulation properties, and involves the following production steps:• Rock wool plate (b) is cut to the desired size.• Rock wool plate (b) is covered with adhesive (c).• The adhesive (c) is compressed by means of a press with chemicals saturated by water, and as a result, tensile strength, compressive strength, and bending strength of insulation member (b) are enhanced.The rock wool with adhesive applied is covered with plaster (b) having higher fire resistance.

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