Note: Descriptions are shown in the official language in which they were submitted.
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English translation of WO 2009/049336 according to IPER
Spacer and structural component for producing a all
construction, and method and device
The present invention relates to a spacer or connection
element for a structural component or formwork unit for the
production of a wall structure including two oppositely
located and substantially parallel, plate-shaped elements
connected by at least two spacers, wherein the free space
between the plate-shaped elements is fillable with an, in
particular, settable mass, e.g. concrete. The present
invention, moreover, relates to such a structural component
or formwork unit for the production of a wall structure, a
method and device for producing such a structural component
or formwork unit, and a wall structure produced in this
manner.
In the context of the production of wall structures, so-
called insulated concrete forming systems are, for
instance, known, in which building or structural components
or shuttering bodies or formwork units comprising
substantially parallel, plate-shaped elements and spacers
arranged therebetween are employed, wherein the free space
between the plate-shaped elements is, for instance,
fillable with concrete such that, after the concrete has
set, the structural components or formwork units will
remain there as a lost formwork or shuttering and, if
produced of synthetic materials, will directly serve as
wall insulation means. In this context, embodiments are,
for instance, known, in which the spacers are made of
metallic materials, polypropylene or similar plastics
produced, for instance, by injection molding.
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Such formwork units or structural components and spacers as
well as production methods thereof can, for example, be
taken from US-B 6 308 484, DE-A 3 502 415, EP-A 1 002 911
or US-B 5 708 060.
Those embodiments involve the drawback that the spacers and
plate-shaped elements of synthetic material, which are
directly used as wall insulation means after the completion
of the wall structure, are, thus, comprised of different
materials, which will create problems in the disposal of
such components or formwork units. Taking into account the
different materials, also different methods for producing
the spacers and the plate-shaped elements are, moreover,
required, the spacers being mostly produced in a separate
production plant and, after transportation to the
production plant of the plate-shaped elements, being used
to form the desired structural components or formwork
units. Furthermore, the spacers, which are usually made of
synthetic materials by injection molding, are extremely
expensive such that, in the main, comparatively high
production costs will occur for such structural components
or formwork units. Besides, such known structural
components, due to the different materials employed, are
prone to damage in the regions of embedment of the spacers
in the plate-shaped elements, since a reliable connection
between the different materials of spacers and plate-shaped
elements is, as a rule, not or only insufficiently
achievable.
When producing such structural components or formwork
units, it must, moreover, be taken into account that the
spacers or connection elements have comparatively small
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cross sections between the plate-shaped elements, since an
excessive weakening of the wall structure to be produced is
to be feared in the region of such spacers. Furthermore,
spacers having large cross-sectional areas are not suitable
for ensuring appropriate fire protection, since spacers
made of synthetic materials may burn through in case of
fire if provided with larger cross sections.
Additionally, it is to be taken into consideration that
partially high forces will have to be taken up by the
spacers both during the filling procedure of the curable or
settable mass, e.g. concrete, and during the subsequent
compaction and setting process such that the spacers will
have to exhibit accordingly high mechanical strengths. As
already indicated above, the use of different materials for
the spacers and the plate-shaped elements entails the risk
of damage and breaking-out occurring in the region of the
embedment of the spacers in the plate-shaped elements on
account of the absent or only insufficiently present
connection of the different materials, so that the
shuttering function to be provided during the filling
procedure and the setting process will not be reliably
fulfilled.
The present invention aims to further improve a spacer or
connection element for a structural component or formwork
unit, such a building or structural component or shuttering
body or formwork unit for the production of a wall
structure as well as a method and device for producing such
a structural component or formwork unit, to the effect that
the above-mentioned prior art drawbacks will be avoided
while providing, in particular, in a simple and reliable
manner, a spacer or connection element as well as a
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structural component or formwork unit for the production of
a wall structure, which exhibit the strength required for
the production of a wall structure and are also able to
meet other demands. In addition, it is aimed at providing a
spacer or connection element as well as a structural
component or formwork unit, which can be made available at
low production costs.
To solve these objects, a spacer or connection element of
the initially defined kind is essentially characterized in
that the spacer is made of expandable polystyrene of
elevated density. Due to the fact that the spacer according
to the invention is made of expandable or foamed
polystyrene (EPS) of elevated density, it is ensured that
the mechanical strength required for the production of a
structural component or formwork unit will also be provided
by a spacer made of expandable polystyrene. By using a
spacer or connection element of expandable polystyrene, it
is feasible to provide an accordingly cost-effective spacer
which can be produced by molds or forms that are simpler
and less expensive, especially in view of injection molding
techniques.
Furthermore, as will be explained in more detail below,
also the plate-shaped elements additionally provided for
the production of the structural component or formwork unit
are, for instance, preferably likewise made of expandable
polystyrene such that, in the main, a complete structural
component or formwork unit can be produced of a uniform or
identical material in a single production plant, thus
enabling the plants required for the production of such a
completed structural component or formwork unit to be made
available at reduced costs. In addition, as will be
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explained in detail below, also an accordingly enhanced
connection between the spacer or connection element and the
plate-shaped elements will be provided by the production of
the structural component or formwork unit according to the
5 invention and, in particular, by using a uniform material.
In order to obtain a suitable mechanical strength of the
spacer when using an expandable polystyrene, it is proposed
according to a preferred embodiment that the density of the
expandable polystyrene of the spacer is selected to range
between 50 and 250 g/l, preferably from about 70 to 160 g/l
and, in particular, from about 70 to 100 g/l. By using such
an expandable polystyrene of elevated density or high-
density polystyrene in the indicated density ranges, it
will be ensured that the forces occurring during a
subsequent filling and setting process in the production of
a wall structure using the so-called insulated concrete
forming system will be taken up safely. When using
expandable polystyrene with the elevated density indicated,
it is, moreover, safeguarded that, after filling, spacers
having accordingly small dimensions or cross sections will
do to overcome, by accordingly simple means, the prior art
problems mentioned in the beginning, particularly in regard
to an enhanced fire protection and the provision of an
impenetrable element, especially in the longitudinal
direction of the spacer, on account of the small thickness
to be achievable. Such securement against penetration of
the spacer in the longitudinal direction is, for instance,
important in areas of elevated dangers or risks with a view
to providing the required bulletproofness.
In order to obtain the desired strength characteristics and
to provide a proper connection with the plate-shaped
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elements or embeddings in the latter, it is proposed
according to a further preferred embodiment that the spacer
is comprised of a planar element designed with an increased
thickness in its end regions relative to the region located
therebetween, said end regions being receivable in the
plate-shaped elements of the structural component. By
providing a substantially central, planar or bar-shaped
element, the forces to be taken up will be distributed over
accordingly increased cross sections, whereby it is,
moreover, feasible, on account of the end regions having
increased thicknesses or dimensions substantially normally
to the planar element, to ensure the reliable embedding or
anchorage in the plate-shaped elements in the subsequent
production of a structural component or formwork unit.
In regard to providing an applicability as universal as
possible, it is proposed according to a further preferred
embodiment that the spacer, in a cross section, is
substantially double-T-shaped with the T-like ends being
receivable in the plate-shaped elements. Such a double-T-
or I-shape causes the necessary forces to be reliably
distributed over the planar, central or bar region, while
the T-shaped ends are receivable in the plate-shaped
elements or connectable with the plate-shaped elements over
accordingly increased cross sections.
To further promote the subsequent connection with the
plate-shaped element, it is proposed according to a further
preferred embodiment that the spacer is designed to
comprise reinforcements in its end regions, between the
planar region and the end regions. Such reinforcements may
be formed by connections between the substantially central,
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planar elements and the consecutively arranged T-shaped end
regions.
To further increase the mechanical strength, it is proposed
according to a further preferred embodiment that the spacer
is reinforced by reinforcing elements. By using such
additional reinforcing elements embedded in the spacer,
accordingly enhanced mechanical strengths will be provided.
Alternatively, when providing appropriate reinforcing
elements, small material cross-sections for the spacers
will do so as to not only meet the demands in respect to a
small clear cross-section for an enhanced fire protection
and bulletproofness, but also allow for the respective
savings of material for the spacers.
An optionally desired reinforcement of the spacers will be
obtained by embedding or incorporating different
reinforcing elements, wherein it is, for instance, proposed
in this connection that the reinforcing elements are
comprised of loose, optionally hydrophilized, fibers
embedded in the spacer. Such fibers can be provided in a
great number of different embodiments as a function of the
desired, in particular mechanical, properties to be
achieved and also with a view to providing a simple
connection with the material of the spacer, wherein such
fibers may, for instance, have lengths ranging from 3 to 10
mm. Alternatively or additionally, it may be provided that
the reinforcements are comprised of sieve-like or grid-like
or net-shaped reinforcements or rods, which are embedded in
the spacer, as in correspondence with a further preferred
embodiment of the spacer according to the invention.
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In order to obtain enhanced, in particular mechanical,
properties when using accordingly cost-effective and
optionally low-weight reinforcements, it is, moreover,
proposed in a preferred manner that the reinforcements are
made of metallic or synthetic material.
Since the spacers to be used for the production of
structural components or formwork units extend
substantially over the height of the respective plate-
shaped element for providing a desired connection, a
comparatively large amount of material is required for the
production of the spacers, in particular for structural
components or formwork units having larger dimensions. In
order to reduce the material to be employed, it may,
therefore, be provided that the spacer is designed to
include at least one recess, depression or breakthrough
extending substantially normally to its direction of
extension, as in correspondence with a further preferred
embodiment of the spacer according to the invention. Such
recesses or depressions or breakthroughs, thus, allow for
material savings with a view to enabling a cost-effective
production of the spacer and, hence, of the structural
component or formwork unit to be produced. In addition,
such depressions or recesses may, in particular, be used if
provided in marginal or edge regions of the central, planar
element or region for arranging and fixing or positioning
armoring or reinforcing elements to be optionally
additionally received in the wall structure to be produced.
With breakthroughs or recesses formed in the central,
planar region, when subsequently filling in a settable
mass, said mass, e.g. concrete, will also enter the
breakthroughs, so that such breakthroughs will not only
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ensure the respective saving of material in the production
of the spacers, but also provide a connection between the
individual chambers or subregions of a structural component
or formwork unit, between the individual spacers. Moreover,
thermal bridges and cold bridges will be avoided in the
wall structure to be produced.
By arranging breakthroughs or recesses particularly in the
planar or central region, it may, moreover, be ensured that
a clear or average cross section will be accordingly
reduced or limited, which will, in particular, contribute
to an enhanced fire prevention and bulletproofness, as
already pointed out above. In this context, it is proposed
according to a further preferred embodiment that the
spacer, in its planar, central region or element, is formed
with at least one breakthrough to prevent the spacer from
being penetrated by a linear element in its planar region.
By preventing a substantially linear penetration of the
spacer in its planar region or element, it will, thus, be
ensured that a penetration will be prevented even in the
case of optionally larger cross-sections of the spacer. The
entry of the settable material into appropriately provided
breakthroughs or recesses will, moreover, ensure that
direct penetration of the spacer will not be possible even
at a bombardment.
In the context of preventing the spacer from being
penetrated by a linear element, or in a longitudinal
direction, it may, moreover, be provided that the spacer is
curved or cranked, or formed with relatively offset
subregions, particularly in its central region, as in
correspondence with a further preferred embodiment of the
spacer according to the invention. Such a curved or cranked
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design or arrangement of relatively offset subregions can
likewise be produced using accordingly simple forms or
molds and, after filling with a settable or curable
material, will prevent the spacer from being penetrated in
5 a direction corresponding with the central, planar region.
When using expandable polystyrene of elevated density,
spacers with accordingly reduced dimensions or accordingly
reduced thicknesses will do to produce the spacers,
10 wherein, in this connection, it is proposed according to a
further preferred embodiment that the spacer has a
thickness of less than 25 mm and, in particular, about 5 to
mm and, most preferred, 10 to 15 mm.
15 To solve the objects set out in the beginning, a structural
component or formwork unit for the production of a wall
structure including two oppositely arranged and
substantially parallel plate-shaped elements connected by
at least two spacers, wherein the free space between the
20 plate-shaped elements is fillable with an, in particular,
settable mass, e.g. concrete, is essentially characterized
in that the structural component comprises at least two
spacers according to the invention, or a preferred
embodiment thereof, and the plate-shaped elements are made
of expandable polystyrene. It is, thus, feasible, by a
simple configuration, to provide an accordingly resistant
structural component or formwork unit, to which end, as
already pointed out above, simplified production plants
will do by forming both the spacer and the plate-shaped
elements of expandable polystyrene. In this respect, it
should not only to be borne in mind that the same material
is used both for the spacer and for the plate-shaped
elements, but that both the spacer and the plate-shaped
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elements can be produced by accordingly simpler forming
methods requiring less expensive tools as opposed, for
instance, to the more cost-intensive molds required for
injection molding. As likewise already indicated above, by
forming both the spacers and the plate-shaped elements of
expandable polystyrene, it is, moreover, ensured that, by
embedding the spacers and, in particular, their end
portions in the plate-shaped elements, a reliable
connection with the material of the surrounding plate-
shaped elements is provided, wherein, by the application of
foaming methods when using expandable polystyrene, a
connection like a weld or fusion will be realized between
the plate-shaped elements and the end regions of the
spacers. Such a joint or weld provides an accordingly high-
strength connection between the individual elements or
components, whereby the forces occurring during the filling
procedure and/or setting process will be distributed in the
plate-shaped elements over a wide area through said
connection such that accordingly high forces will also be
reliably taken up, without having to fear damage to the
structural components or formwork units according to the
invention, in particular in the region of the connection
between the spacers and the plate-shaped elements. Besides,
a structural component according to the invention will be
simpler and less expensive to dispose of, since it is not
made of different materials requiring separate disposal as
is, for instance, common in the prior art.
In order to achieve the desired strength properties of the
structural component or formwork unit according to the
invention when using spacers of expandable polystyrene, it
is provided according to a further preferred embodiment
that the spacers are formed of an expandable polystyrene
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having an elevated density relative to the material of the
plate-shaped elements.
To produce accordingly light-weight structural components
or shuttering elements, it is, moreover, proposed according
to a further preferred embodiment that the density of the
expandable polystyrene for the plate-shaped elements is
selected to range between 10 and 50 g/l, preferably from 20
to 40 g/l and, in particular, from about 20 to 30 g/l.
For the use of the structural component according to the
invention for the production of a wall structure that is
simple to construct, it is, moreover, proposed that the
plate-shaped elements, on their upper and lower boundary
edges, are at least partially provided with profiles
cooperating with complementary profiles of a further
structural component arranged thereabove or therebelow, as
in correspondence with a further preferred embodiment of
the structural component according to the invention. In
this context, it is proposed according to a further
preferred embodiment that the profiles are formed by
substantially regularly arranged projections and
depressions.
As already mentioned above, such structural components or
formwork units according to the invention are used in a so-
called insulated concrete forming system, wherein the
structural components or formwork units will serve as lost
shutterings, which, taking into account the plate-shaped
elements made of expandable polystyrene will impart
appropriate insulation properties to the completed wall
structure. In order to obtain desired and optionally
different insulation properties as a function of use, it is
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proposed according to a further preferred embodiment that
the plate-shaped elements have different thicknesses.
For providing constructions forming a corner it is proposed
according to another preferred embodiment that partial
regions of the plate-shaped elements form an angle, in
particular a right angle.
To solve the objects set out in the beginning, a method for
producing a structural component or formwork unit for the
production of a wall structure including two oppositely
arranged and substantially parallel plate-shaped elements
connected by at least two spacers, wherein the free space
between the plate-shaped elements is filled with an, in
particular, settable mass, e.g. concrete, is essentially
characterized by the steps of:
producing spacers of expandable polystyrene; and
forming the plate-shaped elements of expandable
polystyrene, in a mold, wherein the spacers are connected
with, or embedded in, the plate-shaped elements in their
end regions.
It is, thus, feasible to produce a structural component or
formwork unit according to the invention by simple steps
and in a joint production plant for providing and
processing expandable polystyrene. It is, thus, for
instance, feasible to produce the structural component or
formwork unit according to the invention for the production
of a wall structure in a joint method, wherein the spacers
are produced of expandable polystyrene of elevated density,
in a first method step, whereupon the plate-shaped elements
are likewise produced of expandable polystyrene, in a
second method step, using, for instance, a joint mold in
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which expandable polystyrenes of different densities are
introduced into the subregions respectively provided for
the spacers and the plate-shaped elements.
Alternatively, and optionally for the provision of simpler
molds, it may be provided that the spacers of expandable
polystyrene are produced in separate molds, as in
correspondence with a preferred embodiment of the method
according to the invention, such that expandable
polystyrenes of different densities are each introduced
into a separate mold for the production of a spacer of
elevated density according to the invention and the plate-
shaped elements of lower density, respectively.
In particular, when producing the spacers in separate
molds, the initially produced spacers are subsequently
placed in a mold as a function of the plate-shaped
elements, as in correspondence with a further preferred
embodiment of the method according to the invention,
wherein, by the subsequent production and, in particular,
foaming of the plate-shaped elements, the latter are
reliably and safely connected directly with the spacers in
the end regions of the same.
In order to obtain accordingly high mechanical strengths of
the spacers, it is proposed according to a further
preferred configuration of the method according to the
invention that reinforcements are embedded in the mold for
the production of a spacer prior to the introduction of the
expandable polystyrene.
To solve the initially mentioned objects, a device for
producing a structural component or formwork unit for the
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production of a wall structure including to oppositely
located and substantially parallel, plate-shaped elements
connected by at least two spacers, wherein the free space
between the plate-shaped elements is fillable with an, in
particular, settable mass, e.g. concrete, moreover, is
essentially characterized by:
means for producing the spacers of expandable polystyrene;
and
means for producing the plate-shaped elements, comprising
at least one mold for receiving the spacers and for
introducing expandable polystyrene for forming the plate-
shaped elements and connecting same with the spacers, or
embedding the spacers in the plate-shaped elements,
respectively.
It will thereby be feasible to do with a simple plant or
device for treating or processing expandable polystyrene,
so as to enable the production of the structural components
or formwork units according to the invention, in
particular, in a cost-effective and reliable manner. As
already pointed out above, a structural component or
formwork unit according to the invention can be
substantially produced in a joint device, with the means
for producing the spacers introducing expandable
polystyrene of an accordingly elevated density, into mold
subregions provided for forming the spacers, wherein, after
the production of the spacers, the plate-shaped elements
are produced of expandable polystyrene and connected with
the spacers, or the latter are embedded in the same.
As already indicated above, it may be provided according to
a further preferred embodiment that separate means for
producing the spacers are provided.
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As already mentioned above, the present invention,
moreover, relates to a wall structure comprised of a
plurality of superimposed and/or adjacently arranged
structural components or formwork units according to the
invention or a preferred embodiment thereof.
In the following, the invention will be explained in more
detail by way of exemplary embodiments schematically
illustrated in the accompanying drawing. Therein:
Fig. 1 is a perspective view of a first embodiment of a
spacer according to the invention, for a structural or
building component according to the invention;
Fig. 2 is a side view of the spacer according to Fig. 1;
Fig. 3 is a top view on a structural component according to
the invention, using a plurality of spacers according to
the invention;
Fig. 4 is a perspective view of the structural component
according to Fig. 3;
Fig. 5 is a view of a modified embodiment of a spacer
according to the invention, Fig. 5a depicting a side view
of the spacer in an illustration similar to that of Fig. 2
and Fig. 5b depicting a section along line Vb-Vb of Fig.
5a;
Fig. 6, in an illustration similar to that of Fig. 5,
depicts another modified embodiment of a spacer according
to the invention, Fig. 6a again being a side view and Fig.
6b a section along line VIb-VIb of Fig. 6a;
Figs. 7 and 8 depict views of further modified embodiments
of spacers according to the invention for the production of
building components or shuttering bodies or formwork units
according to the invention, again in side views similar to
that of Fig. 2;
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Fig. 9 is a schematic, partial top view on a modified
embodiment of a structural component according to the
invention, using mutually crossing or intersecting spacers
according to the invention;
Fig. 10, in an illustration similar to that of Fig. 9, is a
top view on a modified embodiment of a structural component
according to the invention, using spacers extending
obliquely or inclinedly relative to one another and
arranged in the manner of a framework construction;
Fig. 11 is a schematic flow chart of a method according to
the invention for producing a structural component or
formwork unit according to the invention;
Fig. 12, on an enlarged scale, schematically illustrates
the reception or embedment of an end region of a spacer
according to the invention in a plate-shaped element for
the production of a structural component according to the
invention; and
Fig. 13, in a view similar to that of Fig. 4, is a
perspective view of a structural component for forming a
corner of a wall structure according to the invention.
In Figs. 1 and 2, a spacer or connection element is
generally denoted by 1, wherein a plurality of such
connection elements 1, as illustrated in Fig. 3, are used
for the production of a structural component or formwork
unit 2, as will be discussed in more detail below.
The spacer represented in Figs. 1 and 2 is comprised of a
central, planar element or region 3 adjoined by end regions
4, which, in the embodiment illustrated, form a double-T-
shape or I-shape together with the central, planar region
3.
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In addition, reinforcing elements 5 are indicated in the
region of the T-shaped end regions 4, said reinforcing
elements providing an enhanced anchorage effect, in
particular, if the spacers 1 are embedded in plate-shaped
elements 6 and 7 of the structural component 2.
Moreover, depressions or recesses 8 are indicated in edge
regions of the central region 3 to subsequently receive,
for instance, additional armoring or reinforcing rods, as
will be discussed below.
From Fig. 3, it is apparent that a plurality of spacers 1
are embedded or received in the substantially parallelly
arranged plate-shaped elements 6 and 7, wherein both the
plate-shaped elements 6 and 7 and the spacers are made of
expandable polystyrene.
In order to take up the forces acting on the spacers 1
during the subsequent filling of the structural component
or formwork unit 2 with a settable mass, e.g. concrete, it
is provided that the spacers or connection elements 1 are
made of a polystyrene having a higher density than that of
the plate-shaped elements 6 and 7. In doing so, a range of
50 to 250 g/l and, in particular, about 70 to 100 g/l, may
be chosen for the density of the spacers 1, while
polystyrene having a density of below 50 g/l and, for
instance, about 20 to 30 g/l is used to obtain the usually
desired insulation properties by the plate-shaped elements
6 and 7 designed as a lost shuttering.
From the illustrations according to Figs. 3 and 4, of the
structural component or formwork unit 2, it is, moreover,
apparent that the plate-shaped elements 6 and 7, on their
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upper and lower sides, are designed to include profiles
formed by elevations or projections 9 and depressions 10,
which cooperate with respectively corresponding profiles of
structural components 2 arranged beside, above or below the
same, in order to provide a wall structure having an
appropriate height extension by the stacking of such
structural components 2 one above the other.
Fig. 4, moreover, indicates the arrangement of an
additional armoring or reinforcement rod 11. According to
demands, several reinforcing rods may, of course, be
arranged in the respective depressions or recesses 8 of the
individual spacers or connection elements 1. Furthermore,
when arranging structural components 2 one above the other,
additional reinforcing elements may also be incorporated in
the vertical direction, which, if required, may be
connected with the reinforcing elements arranged, for
instance, in the horizontal direction in a manner similar
to the reinforcing rod 11.
From the enlarged illustration according to Fig. 12, it is
apparent that the T-shaped end region 4 of a just partially
illustrated spacer 1 is accordingly embedded in the plate-
shaped element 6 or 7, respectively, wherein, considering
the fact that expandable polystyrene is used both for the
spacer 1 and for the plate-shaped elements 6 and 7, a
direct connection or weld or fusion is effected between the
T-shaped end region 4 and the surrounding region of the
material of the plate-shaped elements 6 and 7. Because of
the connection provided by using the same material both for
the spacer 1 and for the plate-shaped elements 6 and 7,
forces occurring during the filling procedure and/or
setting process will, thus, be introduced into the plate-
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shaped elements 6 and 7 over an enlarged partial area, as
is indicated by the lines of force 12, so that no damage in
the region of the reception of the, in particular, T-shaped
end regions 4 in regard to tearing-out from the plate-
shaped element 6 or 7 need be feared.
Fig. 5 depicts a modified embodiment of a spacer 13,
wherein it is to be seen that the planar, central region
adjacent the, in particular, T-shaped end regions again
denoted by 4, is subdivided into two subregions 14 and 15
which are mutually offset in a central portion 16. The
offset arrangement of the subregions 14 and 15 ensures that
no linear passage through the spacer 13 is enabled such
that an accordingly good resistance, in particular, against
piercing of the spacer 13 or shooting through the same will
be safeguarded.
Also in the embodiment illustrated in Fig. 5, additional
reinforcements 5 are again indicated in the region of the
T-shaped end pieces 4. Breakthroughs or recesses 8 are
again provided for accommodating reinforcements.
In the modified embodiment represented in Fig. 6, it is
apparent for a spacer 17 that the central, planar region is
comprised of three relatively offset subregions 18, 19 and
20 so as to again prevent a linear passage through the
spacer 17.
In Figs. 7 and 8, further modified embodiments of spacers
21 and 22 are illustrated, for which it is apparent that by
the arrangement of at least one breakthrough or recess 23
or 24 and 24', respectively, it will each be ensured that a
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substantially linear passage through the spacer or
connection element 21, 22 will again be impossible.
In the embodiment illustrated in Fig. 7, substantially
circular breakthroughs 23 are arranged in a relatively
offset manner, while in the embodiment according to Fig. 8,
recesses or depressions 24 and 24' mutually crossing in the
central region are each provided substantially over one
half of the thickness of the spacer 22.
In addition to providing the possibility of preventing
linear passage, the breakthroughs or recesses 23 and 24,
24', respectively, in the embodiments according to Figs. 7
and 8, moreover, ensure that adjacent subregions or
chambers between individual spacers 21 and 22 will be
connected when being filled with the settable mass, by the
settable mass entering the breakthroughs 23 and 24, so as
to provide a mechanical connection between neighboring
subregions separated from each other by the spacers 21 and
22.
Furthermore, the fire protection properties of the
embodiments depicted in Figs. 5 to 8 will be enhanced,
since an immediate burning-through through curved or
buckled or offset configurations is impossible, wherein an
immediate breaking-through of a spacer 21 or 22 will
likewise be avoided by the arrangement of breakthroughs 23
and 24, 24', respectively.
In Figs. 9 and 10, further modified embodiments of spacer
arrangements between plate-shaped elements again denoted by
6 and 7, of a structural component 2 are indicated. In the
embodiment according to Fig. 9, mutually crossing or inter-
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secting spacers 25 are indicated, while in the embodiment
according to Fig. 10, spacers 26 which are arranged
obliquely or inclinedly relative to the substantially
parallel elements 6 and 7 are shown. These spacers 25 and
26 are again embedded in the plate-shaped elements 6 and 7
via substantially T-shaped end regions 4, further forming
being, for instance, realized in a manner similar that of
the spacers illustrated in the preceding embodiments.
In order to achieve optionally increased strength
characteristics, it may, moreover, be provided that
reinforcement elements comprised, for instance, of fiber
reinforcements or sieve-like reinforcing elements are
embedded in the spacers 1, 13, 17, 21, 22, 25 and 26 by
being respectively incorporated in the spacers 1, 13, 17,
21, 22, 25 and 26 at the production of these spacers,
during the foaming procedure of the expandable polystyrene
of elevated density.
In particular, when providing reinforcements, which may,
for instance, be made of synthetic material or metal,
spacers 1, 13, 17, 21, 22, 25 and 26 having accordingly
reduced cross sections or reduced thicknesses will do yet
while maintaining the required and, in particular,
mechanical properties. For the central, planar region,
thicknesses of about 5 to 20 mm and, in particular, 10 to
15 mm, will, for instance, do at accordingly elevated
densities of the expandable polystyrene used for the
production of the spacers 1, 13, 17, 21, 22, 25 and 26.
Fig. 11 schematically depicts a process diagram for the
production of a structural component or formwork unit 2,
wherein, in a first step S1, the production of a spacer 1,
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13, 17, 21, 22, 25 and 26 is effected, to which end
expandable polystyrene of an accordingly elevated density
is introduced into a mold.
After the production of the spacers 1, 13, 17, 21, 22, 25
and 26 in step Si in a separate device, these spacers are
placed in a mold for the production of the structural
component or formwork unit 2 in a step S2, after which, in
a further step S3, the plate-shaped elements 6 and 7 are
likewise formed by introducing expandable polystyrene into
a mold corresponding with the plate-shaped elements 6 and
7. Due to the accordingly elevated temperatures occurring
during the foaming procedure, a connection between the
material of the plate-shaped elements 6 and 7 as well as
the spacers likewise produced of expandable polystyrene of
elevated density is immediately realized in the form of
welding or fusing together as explained in detail with
reference to Fig. 12.
Bearing in mind the method steps represented in the process
diagram according to Fig. 11, a structural component or
formwork unit 2 can, thus, be produced using an accordingly
simple device, wherein a separate device or, in general,
means for producing the spacers 1, 13, 17, 21, 22, 25 and
26 is provided according to step Si.
Moreover, means or device for producing the structural
component 2 by arranging the spacers in a suitable mold and
subsequently foaming the plate-shaped elements 6 and 7 for
connection with the end regions 4 of the spacers 1, 13, 17,
21, 22, 25 and 26 is provided according to steps S2 and S3.
In this respect, the automatic transfer into the mold, of
the spacers 1, 13, 17, 21, 22, 25 and 26 produced in the
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device according to step S1 may, for instance, be provided
to perform steps S2 and S3.
Instead of the process diagram represented in Fig. 11, in
which the spacers 1, 13, 17, 21, 22, 25 and 26 are produced
in a separate device in step Si, a joint mold may be
provided for the production of both the spacers 1, 13, 17,
21, 22, 25 and 26 and the plate-shaped elements 6 and 7,
wherein expandable polystyrene of an accordingly elevated
density is introduced into, and treated and processed in,
the subregions of the mold, in which the spacers 1, 13, 17,
21, 22, 25 and 26 are to be produced subsequently,
whereupon, in consecutive step S3, the plate-shaped
elements 6 and 7 are formed by introducing expandable
polystyrene of an accordingly lower density into the mold
in correspondence with the plate-shaped elements 6 and 7,
while effecting a connection with the spacers 1, 13, 17,
21, 22, 25 and 26, or embedment of the latter in the plate-
shaped elements 6 and 7.
When providing such a joint mold for the production of both
the spacers 1, 13, 17, 21, 22, 25 and 26 and the plate-
shaped elements 6 and 7, the additional method step S2 of
transporting or transferring the spacers 1, 13, 17, 21, 22,
25 and 26 produced in a separate device in step S1 can be
obviated. When using such a method and such a device,
respectively, it must, however, be made sure that as
starting material expandable polystyrenes of different
densities will be available for the production of the
spacers 1, 13, 17, 21, 22, 25 and 26 as well as the plate-
shaped elements 6 and 7 in consecutive steps and different
mold subregions.
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With an embodiment according to Fig. 13 plate-shaped
elements are once more indicated with 6 and 7, wherein it
can be seen that for forming or producing a structural or
building element or block of a corner the plate-shaped
elements are each comprised of partial regions 6', 6" as
well as 7' and 7" forming or comprising an essentially
right angle there between, each of which can be formed
integrally in a respective mould.
Spacers similar to the embodiment of Fig. 4 are once more
depicted as 1, wherein it can bee seen that in the region
of the corner or edge a spacer 1' is positioned essentially
diagonally, whereas the other spacers 1 in the regions of
the partial regions being formed by the elements 6' and 7'
or 6" and 7" are positioned essentially orthogonally to the
plate-shaped elements 6 and 7 cooperating therewith as with
the previous embodiments.
Similar to the previous embodiments moreover profiles in
the form of projections 27 and recesses 28 are arranged or
formed for a coupling or for a connection with structural
elements 2 being positioned above or below.
Instead of the recesses 8 illustrated in the Figures, an
accordingly modified number and/or form or shape may be
provided for the recesses or depressions 8 to accommodate,
for instance, armoring rods or reinforcing elements.
In addition to the circular or elliptical or rounded-off
recesses or breakthroughs 23 and 24, 24' shown in Figs. 7
and 8, recesses or breakthroughs having accordingly
modified, e.g. rectangular, square, etc., cross sections
may be provided.
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In addition to avoiding a substantial linear passage
through a spacer by providing breakthroughs or recesses 23
and 24, 24', such breakthroughs or recesses will also
ensure an accordingly large saving of material for the
formation of the spacers 21 and 22.
By forming both the spacers 1, 13, 17, 21, 22, 25 and 26
and the plate-shaped elements 6 and 7 each of expandable
polystyrene an optionally required disposal of such
structural components or formwork units 2, or wastes
thereof, will also be facilitated in that no separation
into individual elements or components is required, as has
been the case with known embodiments.
It is, moreover, feasible to use a simple and cost-
effective mode of realizing the processing of expandable
polystyrene for the production of the spacers 1, 13, 17,
21, 22, 25 and 26, in particular, as opposed to known
injection molding techniques.
Furthermore, the end regions 4, instead of comprising the
T-shapes illustrated, may have modified shapes, whereby
reliable embedding in the plate-shaped elements 6 and 7,
respectively, will, in particular, be feasible by providing
an appropriate thickness or dimension of the end region 4
relative to the central element or region 3 as is, in
particular, illustrated in Fig. 12.
