EP0239053B1 - Prefabricated roller shutter box composed of assembled brick elements, and method for producing it - Google Patents

Abstract

In a prefabricated roller shutter box (1) of moulded bricks (2, 3, 4, 5) which have in cross section a roller shutter box profile in the form of an inverted U of two side webs (6, 7) and a centre web connecting these and are connected to one another by bonding agents and reinforcements, the reinforcements consist of rails (14, 15) resting against the ends (12, 13) of the two side webs (6, 7), extending essentially over the entire length of the roller shutter box (1) and connected to the ends by means of bonding agents, which reduces production time and manual effort. Independently of this, reinforcement rods can be used, particularly in the case of slotted moulded bricks. <IMAGE>

Description

The invention relates to a prefabricated roller shutter box made of abutting brick blocks, which in cross section form a roller shutter box profile in the form of an upside-down U from two side webs and a central web and reinforcements connecting them.

A prefabricated roller shutter box of this type is known (DE-PS 25 36 086), in which reinforcement slots are provided on the end faces of the side webs and on the inner surfaces of the shaped bricks forming the roller shutter box profile. A disadvantage of this type of construction is that the naturally relatively narrow reinforcement slots have to be filled laboriously by hand with a trowel with binding agent, primarily cement mortar, in order to embed the reinforcement bars. This form of handwork is also lengthy and therefore labor-intensive.

The object on which the invention is based, on the other hand, is seen in creating a roller shutter box which is not only particularly stable, but can also be produced more easily and in a time-saving manner with less manual effort.

This object is achieved in that the shaped bricks of a shutter box in their corners, on each of which the side webs and the central web collide, and also in the region of the ends of the two side webs have continuous, mutually aligned perforated channels, in which reinforcing bars embedded in binders are inserted, that at the end faces of the roller shutter box each end plates by means of dowels or by means of the ends of holes positioned in the end plates Reinforcing bars seated bushes or spring clips or the like are attached to the brick blocks, and that the end plates have bearings for the respective roller shutter and other holes for the introduction of binder in the perforated channels.

These reinforcing bars ensure the strength of the roller shutter box and can also be used, for example, for roller shutter boxes intended for plaster masonry, if necessary in addition to existing rails or profile rails, where a particularly large length of the roller shutter box makes additional reinforcements appear appropriate.

Advantageously, the shaped bricks that are used for the construction of the prefabricated roller shutter box can also be so-called brick boards, if necessary already reinforced before assembly, in which case one brick board forms the central web and two brick boards the side webs of the upside-down U. The connection of the brick boards can be done by edge grooves in the brick board forming the central web on the one hand and in the brick boards forming the side webs on the other hand, which form the channels for the reception of reinforcing bars and binders when they are joined together. The on the end faces of the roller shutter box by means of dowels or through bushings that sit on the reinforcing bars, or spring clips or the like, to the End plates made of metal attached to brick form a particularly stable bond. It is particularly advantageous that these end plates already have bearings for the respective roller shutter shaft.

Furthermore, the end plates have further holes for the introduction of binder into the hole channels.

The use of cuboid shaped bricks enables smaller wall thicknesses after U-shaped or angular shaped bricks need thicker walls to avoid warping during the firing process. Brick boards are much less prone to warping and are therefore cheaper in terms of both material consumption and manufacturing costs. The brick boards can of course be made in advance from a series of cuboids and also reinforced before a roller shutter box is formed from three brick boards. Preferably, however, the cuboid bricks, preferably elongated brick, forming the central web and the side webs, preferably elongated brick, are placed in a U-shaped form on the back, the bricks forming the central web and the side webs having grooves on their abutting edges, the channels with one another form, into which the reinforcements are subsequently introduced or drawn in, whereupon the binder is pressed in.

The usual structural steels can be used as reinforcements for use in the channels or perforated channels of the shaped bricks.

According to a preferred method for producing a prefabricated roller shutter box according to the invention, the brick blocks forming a roller shutter box are joined together with or without an intermediate layer of binder, and the reinforcing bars are then inserted into the channels of the brick blocks which are aligned with one another, whereupon binder is pressed into the channels. Since the binder, for example cement mortar, can dry out too early due to the absorbance of the brick and, moreover, the friction of the binder on the perforated channel wall would be relatively high, which would require considerable pressures, the binder is expediently introduced by means of a lance, each parallel to a reinforcing bar inserted into the same channel and withdrawn accordingly during the filling process, it has proven useful to withdraw the lance in batches in such a way that the space between the reinforcing bar and the channel wall is only acted on in the area of the shaped blocks, but not in the area of their joints, thereby leaving proceed in such a way that the binding agent nevertheless flows into the joints between two shaped stones without, for example, splashing out of two abutting shaped stones between the end faces.

More complex is the use of pipes as reinforcing bars, the outer diameter of which is smaller than the inner diameter of the channels and the wall of which has openings distributed along the circumference of the pipe. On the one hand, this results in an improved stability of the roller shutter box corresponding to a better dimensional stability of a tube compared to a solid rod, on the other hand, the tubes can also be self-made use as lost lances, so to speak, which then leaves no possibility for batch filling of the pipe and the space between the reinforcement pipe and the duct wall. Only by using an additional lance, which is inserted into the respective tube and in turn withdrawn accordingly during the filling process, can it be ensured that batches of binder are pressed into the tube and through its openings penetrates into the space between the tube and the brick, in each case where this is desired.

A mortar press can be used simply and advantageously for the introduction of the binder or mortar into the perforated channels of the shaped blocks forming the roller shutter box.

The use of elongated perforated bricks generally leads to better heat insulation properties, weight reduction and material savings.

The invention and advantageous refinements of the same are explained in more detail below with reference to exemplary embodiments shown in the drawing.

Fig. 1

eine erste Ausführungsform des Rolladenkastens nach der Erfindung;

Fig. 2

die Stirnansicht einer Hälfte eines Rolladenkastens in vergrößertem Maßstab;

Fig. 3

eine Einzelheit des in Fig. 2 dargestellten Rolladenkastens;

Fig. 4

einen Ausschnitt aus einer Abschlußdeckelhalterung bei dem Rolladenkasten nach Fig. 5;

Fig. 5

eine weitere Ausführungsform des Rolladenkastens;

Fig. 6

eine stirnseitige Draufsicht auf eine Abschlußplatte eines Rolladenkastens;

Fig. 7

eine Seitenansicht der Ausführungsform nach Fig. 6, teilweise geschnitten;

Fig. 8

eine der Fig. 6 entsprechende Draufsicht auf eine unterschiedliche Ausführungsform;

Fig. 9

eine Seitenansicht der Ausführungsform nach Fig. 7;

Fig. 10

eine Draufsicht auf eine Aussteifungsplatte;

Fig. 11

einen Querschnitt durch einen aus Ziegelbrettern aufgebauten Rolladenkasten;

Fig. 12

einen Querschnitt durch einen Rolladenkasten nach Fig. 10, bei welchem das den Mittelsteg bildende Ziegelbrett durch ein Schaumstoff-Formstück ersetzt ist.

It shows:

Fig. 1

a first embodiment of the roller shutter box according to the invention;

Fig. 2

the front view of one half of a roller shutter box on an enlarged scale;

Fig. 3

a detail of the roller shutter box shown in Figure 2;

Fig. 4

a section of an end cover bracket in the roller shutter box of FIG. 5;

Fig. 5

a further embodiment of the roller shutter box;

Fig. 6

an end plan view of an end plate of a roller shutter box;

Fig. 7

a side view of the embodiment of Figure 6, partially in section;

Fig. 8

6 shows a top view corresponding to a different embodiment;

Fig. 9

a side view of the embodiment of FIG. 7;

Fig. 10

a plan view of a stiffening plate;

Fig. 11

a cross section through a shutter box constructed of brick boards;

Fig. 12

a cross section through a roller shutter box according to FIG. 10, in which the brick board forming the central web is replaced by a foam molding.

The prefabricated roller shutter box 1 shown in FIG. 1 consists of shaped bricks 2, 3, 4 and 5 that abut one another on the end face, which in cross section have a roller shutter box profile in the form of an upside-down U from two side bars 6 and 7 and a central bar connecting them. They are connected to one another by means of a binder and reinforcements introduced between their abutting surfaces, which are indicated by lines 9, 10 and 11 in FIG. 1.

The ends 12 and 13 of the two side webs 6 and 7 of each brick block 2, 3, 4 and 5 forming the respective roller shutter box 1 can lie on rails which extend substantially over the entire length of the roller shutter box 1 and are connected to the side bars 6 and 7 by means of binders 14 and 15. The side and middle webs of the shaped bricks 3, 4 and 5 are not designated separately, since all shaped bricks are of the same design.

The rails 14, 15 can be designed as profile rails, which overlap the ends 12, 13 of the side webs 6, 7, at least on one of their sides. In the case of the profile rail 14 shown on the left in FIG. 1, the same overlaps with an angled web 16 the side of the end 12 facing the interior 17 of the roller shutter box 1. In the case of the one shown in the foreground in FIG. 1, it sits on the end 13 of the side web 7 Profile rail 15 overlaps end 13 on both sides with side webs 21 and 22.

Furthermore, on the outer sides of the two rails 14 and 15 each a substantially vertically extending from the side web 6 or 7 cleaning strip 23 or 24 may be arranged in one piece, from which it follows that the roller shutter box shown in perspective in Fig. 1 is intended for installation in plaster masonry.

The profile rails are attached with the aid of a binder, which can be a plastic-based adhesive or cement mortar or a combination of both, in such a way that an intimate connection of the shaped bricks with the profile rails is achieved.

In the inner corners 55, 56 of the shaped bricks, additional reinforcements in the form of continuous angle rails 57, which extend essentially over the entire length of the roller shutter box and are connected to the shaped bricks by means of binders, can be provided (FIG. 2). Both the corners 56 and the angle rails 57 adapted to them can be rounded. The angle rails 57 can have openings which are formed by continuous grooves 58 formed on the brick. Even where these rails 57 are not required for structural reasons in the installation position of the respective roller shutter boxes, since the profiled rails 14, 15, which sit on the ends 12, 13, 48 and 49 of the side webs 6, 7, 50, 51, 42, 43 are easily sufficient to absorb the loads, the additional rails 57 in the corners 55, 56, as shown in FIG. 2, may be required to accommodate the changing loads that occur during transport, for example loads in which the profile rails are under pressure are stressed so that the angle rails 57, loaded on train, can absorb these additional bending forces. This task can also be performed with binding agent on the top of the roller shutter box or on the outside of the central web 58 or 58 'T-profile rails 57' (FIG. 2), whose webs 68 in engage appropriately molded grooves 56 'of the brick moldings.

As the left half of FIG. 2, and also the rear half of the roller shutter box according to FIG. 1 shows, according to the invention, the shaped bricks of a roller shutter box are at the statically advantageous points, thus at least in their corners, at which the side webs 6, 7 and 50, 51 and the central web 8 or 58, 58 'merge into one another, continuous, mutually aligned perforated channels 59 are provided, in which reinforcing bars 61 embedded in binder 60 are inserted (FIG. 2). In the embodiment according to FIG Corresponding perforated channels and reinforcing bars are provided in the region of the ends of the two side webs, as in the rest of the embodiment according to FIG. 11, see perforated channels 68, in which reinforcements 69 are arranged. The latter figure is a cross section through an embodiment in which the shaped bricks are provided with hollow holes brick boards 70, 71, 72, which may also have been reinforced separately, which is not shown in the present case, but for the rest, however Brick board 70 form the central web and the two brick boards 71 and 72 form the side webs of the U standing upside down. This embodiment is discussed in more detail below.

When assembling the bricks into a row forming the roller shutter box, appropriately shaped wire or sheet metal anchors can be enclosed, through which the reinforcement is inserted, to form transport suspensions.

4 and 5, one possibility is shown to provide the respective end brick bricks 2 'and 5' of a roller shutter box 1 'with a circumferentially formed inner fold 65 or 65', in each of which one End cover 66, 66 'can be inserted and fastened by means of binders. If cutouts have to be provided for this in the respective existing profile rails, these have not been shown, for example, in the embodiment according to FIG. 1 for the sake of clarity. The respective end cover 66 or 66 'engages in the inner fold 65 or 65' by means of a projecting, circumferential collar 67 or 67 '.

In contrast, FIGS. 6 and 7 on the one hand and FIGS. 8 and 9 on the other hand show a further, preferred possibility of closing the end brick shaped blocks 73 or 74 at the end. For this purpose, end plates 75 and 76, expediently made of metal, are fastened to the brick block 73 by means of dowels or, as shown in FIG. 7, by means of bushings 78 sitting on reinforcing bars 77. The end plates 75 and 76 also have bores 79 for fastening the bearings for the respective roller shutter shaft, not shown, and further bores 80 for hanging transport hooks, and finally holes 81 for the introduction of binding agents, which will also be discussed in more detail below .

The embodiment according to FIGS. 8 and 9 differs from that according to FIGS. 7 and 6 only in that a reinforcing tube 82 is used instead of the reinforcing rod 77 in such a way that separate holes 81 (see FIG. 6) in the end plate 76 for the introduction of the binder 83 is unnecessary. Rather, the filling can take place through the pipe 82, not shown, which has no bushes, spring clips or the like at its ends for fastening the end plate 76, since it is only necessary to ensure that a flare 83 'is present which holds the end plate 76 firmly on the end face of the brick 74.

An advantageous embodiment consists in inserting at least one stiffening plate, which in its outer contour essentially follows the outer contour of the roller shutter box, between two brick blocks of the box which abut one another on the end face as reinforcement, which may have openings for additionally required reinforcements. Such a stiffening plate is shown in FIG. 10 and is provided with the reference number 85. Such a stiffening plate 85, which suitably consists of sheet metal, can be inserted, for example, in the embodiment according to FIG. 1 at 10 and serves for additional stiffening and stabilization of the roller shutter box, in particular for those which extend over a greater length and under the influence of occurring tensions to warp, e.g. The sidewalls tend to bulge out. These stiffening plates 85 can have at least one eyelet 87 protruding upwards on their central web 86, which on the one hand serves for transport and on the other hand can be mortared into the masonry lying above and is therefore suitable for serving an intimate connection between the roller shutter box and subsequent masonry.

Such a stiffening plate 85 is particularly advantageous in the embodiments according to FIGS. 11 and 12, namely where the U-shaped roller shutter box profile is made up of brick boards, which in turn consist of individual bricks and are either already pre-armed or are already available or when the Roller shutter box profile can be placed as a single brick in a mold template and then reinforced, after which the binder is introduced. There, these stiffening plates or sheets 85 ensure perfect stability, in particular at the joints of the center webs and side webs, in such a way that in the embodiment according to FIG. 12 the brick board forming the center web (FIG. 11) is formed by a rigid foam molding 88 can be replaced, which serves a particularly good insulation and weight reduction. Apart from this, the two embodiments according to FIGS. 11 and 12 can be made much narrower with sufficient freedom for the roller shutters to be accommodated than would be the case with roller shutter boxes composed of angular brick blocks or U-shaped brick blocks, so that they can also be installed in thinner masonry , for example, only 30 cm thick, is possible, and in the embodiment according to FIG. 11 it is also possible to insert additional thermal insulation in the form of foam. In the embodiment according to FIG. 12, the foam molding 88 has on one side an extension 91 lying flat along the inside 90 of one of the two brick boards forming the side webs, in this case the brick board 72. It is understood that in this case the brick board 72 faces the interior of the building in which the finished roller shutter box is installed. In the embodiment shown, the foam molding also has integrally formed webs 107, 108 which engage in reinforcement channels 109, 110 and increase the stability even before the binder 111 is introduced in addition to the reinforcement rods 112, 113. In the embodiments according to FIGS. 11 and 12, the same reference numerals are also used for the same parts.

The foam molding 88 can be made of polystyrene, polyurethane or the like.

Where reinforcing bars 77 or reinforcing pipes 61 (FIG. 2) require this, the stiffening plate 85 must of course have corresponding openings 89 which are essentially congruent with the continuous channels into which the reinforcing bars or pipes are inserted. The process for producing a prefabricated roller shutter box according to the invention is characterized in that the brick blocks forming a roller shutter box are joined together with or without an intermediate layer of binder and then the reinforcing bars are inserted into the channels of the brick blocks which are aligned with one another, whereupon binders is pressed into the channels. If necessary, one or more stiffening plates 85 are introduced when joining the shaped bricks and, in addition, end plates 75 and 76 are added. The binding agent is expediently introduced with a lance (not shown), which is inserted parallel to the reinforcing rod 77 into the same channel 90 (FIG. 7) through a hole 81 in the end cover 75 and is correspondingly withdrawn during the filling process.

The lance is expediently withdrawn in batches such that the space between the reinforcing rod 77 and the perforated channel wall is only acted on in the area of the shaped blocks, but not in the area of their joints, in order to prevent the binder pressed in under considerable pressure by means of a mortar press, not shown.

If the reinforcing rods are pipes 61 (FIG. 2) or 82 (FIG. 9), then their outer diameter d is smaller than the inner diameter D of the perforated channels 59 and 84, the wall 62 of the pipes having openings 63 distributed along the pipe circumference, such as this shows Fig. 3. It has already been pointed out that when tubes are used, the lance is introduced into the tube in order to release the binder and to be withdrawn accordingly during the filling process. However, the tubes can also be left as lost lances in the channels, as is shown in the embodiments according to FIGS. 2 and 9.

The reinforcement rails described with reference to FIGS. 1 and 2 expediently consist of a non-rusting material such as stainless steel, galvanized steel, aluminum or plastic.

In this context, it is pointed out that the rails 114, 115 in the embodiment according to FIGS. 11 and 12 can be both reinforcement rails, regardless of whether the reinforcement rods 69 are present or not, and also simply snap-on, possibly as here plaster strips 116 having rails. At 117, a support strip for foam fittings is also provided.

Furthermore, it is pointed out that in the embodiment according to FIG. 12, instead of the webs 107, 108, grooves can also be provided in the fitting, comparable to the grooves 118 and 119 in the edges of the brick board 70 according to FIG. 11, such that the binder 111 flows into the channel 109, 118 or 110, 119 (see FIG. 11) which forms and thus flows into both the side webs and the central web.

Claims (12)

1. Prefabricated roller shutter box composed of brick elements abutting each other, said brick elements in cross section establishing a roller shutter box profile in the form of a U-shaped beam with its upside down and consisting of two side webs, a center web connecting same, and reinforcements, characterized in that the brick elements of a roller shutter box (1) in their corners where the side webs (6, 7; 50, 51; 70, 71) and the center web (8; 58, 58'; 70) meet each other respectively, and also in the area of the ends of each of the two side webs, the brick elements comprise penetrating channels (59; 109, 118; 110, 119) or tunnels, respectively, which are aligned with each other and into which reinforcing rods (61, 69, 77, 112, 113) embedded into a binder or cement (60, 111) are inserted, that at each front side of the roller shutter box (1) closure plates (75) are secured to the brick elements (73) by means of plugs or by means of bushings (78) or spring clamps or the like which are placed on the ends of said reinforcing rods (77), said ends being positioned through holes in the closure plates (75), and that the closure plates (75) comprise bearings for the respective roller shaft and additional holes (81) for the introduction of binder or cement, respectively, into the penetrating channels or tunnels, respectively.
2. Prefabricated roller shutter box according to claim 1, characterized in that the brick elements are brick boards (70, 71, 72) which are optionally already reinforced, wherein one brick board (70) forms the center web and two brick boards (71, 72) form the side webs of the U with its upside down.
3. Prefabricated roller shutter box according to claim 2, characterized in that the brick board forming the center web is replaced by a stiff form piece (88) made of foam.
4. Prefabricated roller shutter box according to claim 3, characterized in that the foam form piece (88) at its one side comprises an extension which abuts tabularly along the inner side (90) of one of the two brick boards (72) forming the side webs.
5. Prefabricated roller shutter box according to claim 4, characterized in that the foam form piece (88) consists of polystyrene or polyurethane.
6. Prefabricated roller shutter box in accordance with at least one of the preceding claims, characterized in that at least one U-shaped stiffening plate (85) is inserted as a reinforcement between two brick elements of the box which face each other, said stiffening plates having openings for the reinforcing rods, if necessary.
7. Prefabricated roller shutter box according to claim 6, characterized in that the stiffening plate (85) comprises at least one eye (87) extending upwardly at its center web (86).
8. Prefabricated roller shutter box according to claim 7, characterized in that the stiffening plate (85) is made from sheet metal.
9. Prefabricated roller shutter box according to one of the preceding claims, characterized in that the bricks or brick elements used are perforated bricks.
10. Method for the manufacture of a prefabricated roller shutter box according to one of claims 1 to 9, characterized in that the brick elements forming a roller shutter box are put together with or without an intermediate layer of binder or cement, respectively, and that consecutively the reinforcing rods are inserted into the penetrating channels or tunnels, respectively, which are aligned with each other, following which binder or cement, respectively, is pressed into the channels.
11. Process according to claim 10, characterized in that the binder or cement, respectively, is inserted by means of a lance which is introduced parallel to the reinforcement rods (69; 112, 113) into the same channel (68; 109, 118, 110, 119) and which is retracted during the filling process, respectively.
12. Method according to claim 11, characterized in that the lance is retracted step by step such that the space between reinforcing rod (69; 112, 113) and channel wall will be impinged only in the area of the brick elements, not in the area where the brick elements abut each other.

Images