EP3625021A2

EP3625021A2 - Method of manufacturing a building element for thermal insulation, method for filling cavity with insulating material in a building element and building element for thermal insulation

Info

Publication number: EP3625021A2
Application number: EP18740354.8A
Authority: EP
Inventors: Marek BANIECKI
Original assignee: Baniecka Iwona
Current assignee: Baniecka Iwona
Priority date: 2017-03-25
Filing date: 2018-03-23
Publication date: 2020-03-25
Also published as: WO2018182438A3; WO2018182438A2

Abstract

In accordance with the present invention, there is provided method of manufacturing a building element for thermal insulation characterized in that, the known components for producing an open-cell or a closed-cell polyurethane foam are being prepared. The method comprising the step of supplying each of components separately under pressure towards the hollow space of the block or the likes that mixing both components at the inlet of the hollow space with using of nozzles. The method of components supplying is performed in such a way that an open-cell or the closed-cell polyurethane foam is obtained in the interior space of a hollow block and not before. In further embodiment of the invention, the components are being supplied into the mould for producing shaped profile made of polyurethane foam. The hollow space of the building element is being filled with the profile.

Description

Method of manufacturing a building element for thermal insi

with insulating material in a building element and building element for thermal insulation

The present invention relates to a method of producing an element for building construction made of the building elements in a form of hollow blocks or bricks or the likes, with the cavities in the bricks or blocks being filled that provides thermal insulation. The present invention relates to a method of filling a building element cavity with insulating material, the element being in the form of hollow block or the likes. The invention relates to a building element for thermal insulation obtained by the method. The invention is to be used to provide thermal insulation for construction in particular of residential and industrial buildings.

The conventional materials to provide thermal insulation of buildings are Styrofoam - polystyrene foam, and mineral wool. The polystyrene foam is produced of polystyrene by granules, particles foaming that merge under high temperature and high pressure performance and simultaneously the volume of produced foam is recursively multiplied. Because of its spongy structure, the polystyrene foam is characterized with low thermal conductivity ratio. However, polystyrene foam is characterized with no vapor permeability and sensitivity to some chemicals, in particular organic diluents, saturated hydrocarbons, benzene, oils, greases, kerosene, oil derivatives, that restrict number of means for bonding of produced polystyrene foam. The mineral wool is the other popular insulating material. The main disadvantage of mineral wool using is its high moisture absorption and tendency to subsidence in course of time.

There are known slabs made of foamed polystyrene or mineral wool that are used in thermal insulation systems.

The use of prepared foam - foamed polystyrene in filling of hollow building elements with in particular blocks or bricks to make a construction element to be used as a building element for building construction, in particular walls, is known. It is also known such use of clay hollow bricks filled with mineral wool.

Patent application DE 3006008 discloses the method of hollow building blocks filling with before foamed and mixed with adhesive binder polystyrene and the prepared insulating mixture is pumped into the block hollows.

Patent application EP 1854620 discloses the method for filling cavities with previously foamed with high temperature air polystyrene or with foamed polypropylene.

The thermal conductivity ratio of the known hollow block that are filled with polystyrene foam is U=0,15 W(m²*K). In case of the structural clay bricks that are filled with mineral wool, the thermal conductivity ratio is U=0,17 W/(m²*K). The main drawback of the known building insulating elements is high costs of production of them.

It is still a need to provide a material for building construction made of building elements in order to manufacture element with high thermal insulation and to lower costs of obtaining the elements. It is also expected for such building elements to make building thermal insulation construction work simplified and shortened in time.

The object of the present invention is to provide a methodology of interior space of hollow building elements, in a form of hollow blocks or the likes, filled with an insulating material. Unexpectedly, it has turned out that manufacturing of an open-cell or a closed-cell polyurethane foam in such a way that the polyurethane foam is being produced and obtained directly in the interior space of a building element or is being produced in a mould that shape is properly adjusted to hollow space of the building element, enables to fill tightly an internal space and fill the hollow space tightly sealed, that it is not achieve when hollow building element are being filled with prepared insulating materials that are manufactured before products. The methodology makes thermal insulation of building constructing time shorten and lower costs of building and construction materials production. In case when the mould is used to obtain an insulating material for filling the particular hollow building element, the shaped profile made of foam that is obtained after being removed from the mould, is located inside the interior space in the building element by being mechanically compressed to the sizes that enables a polyurethane foam profile to fill the hollow building element in a tight way. In case when hollow building element are directly being filled with insulating material, the polyurethane foam is being produced and is obtained only and directly in interior space of the hollow building element in its cavity as a result of chemical reaction between two fluid components that are supplied into the interior space with separate nozzles using. The polyurethane foam making components are supplied under pressure with using of nozzles and during that the components streams are mixed at the level of the inlet into the interior space of the building component. Depending on the embodiment of the invention, the components mixing is performed directly at the outlet of the nozzle of an airbrush or automatic injector with multiple nozzles. In a further embodiment, the components are supplied into the before prepared mold to obtain the polyurethane foam shape - profile with that the interior space of the building element is subsequently filled to obtain insulating material inside the building element.

Thus, in accordance with the present invention, there is provided method of manufacturing a building element for thermal insulation characterized in that, the known components A and B for producing an open-cell or a closed-cell polyurethane foam are being prepared, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound. The method comprising the step of heating the A and B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components separately under pressure towards the hollow space of the block or the likes that mixing both components at the inlet of the hollow space with using of nozzles. The method of components supplying is performed in such a way that an open-cell or the closed-cell polyurethane foam is obtained in the interior space of a hollow block and not before.

Preferably, the interior space of the hollow block is being filled with polyurethane foam components to obtain an open-cell polyurethane foam of density range from 5 to 12 kg/m3.

Preferably, the interior space of the hollow block is being filled with polyurethane foam components to obtain a closed-cell polyurethane foam of density range from 25 to 60 kg/m3.

Preferably, a building concrete block or a clay building block or a perlite block is used as a type of the block.

Preferably, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

Preferably, the polyurethane foam components are being supplied towards the hollow space in the block with injecting nozzle at the pressure value at the outlet of the nozzle of at least 3.0 MPa.

Preferably, a through-hole is being created within each of the side wall of the block in such a way that the through-hole is created on a length from 20% to 80% of the brick side wall length and then through-hole is being filled with polyurethane foam to form a separation made of a polyurethane foam in the side wall of the block.

Preferably, at least one pair of the tongue and groove joint is being formed within side wall of the block.

Preferably, at least one pair of the tongue and groove joint is being formed within the created separation filled with polyurethane foam, wherein the first part of the joint is formed within the separation of the first side wall of the block and the second part of the joint is formed within the separation of the second side wall of the block while the tongue part and the groove part of the joint are located in a parallel and opposite relation to each other.

In accordance with the present invention, there is provided the method of manufacturing a building element for thermal insulation characterized in that, the interior space of the block or the likes is being divided into two basic cavities each being hollow space of the block that separately adhere to each other longitudinally. The first cavity is a space limited by at least the front wall length of the block and the first cavity width amount to at least 3 mm. The second cavity is a space limited by at least back wall length of the block. Then known components A and B are being prepared for producing an open-cell polyurethane foam and the known components A and B are being prepared for producing a closed-cell polyurethane foam, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound. The method comprising the step of heating the A components and the B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components for producing a closed-cell polyurethane foam separately under pressure towards the hollow space of the first cavity that mixing both components at the inlet of the first cavity with using of nozzles and supplying each of the A and B components for producing an open-cell polyurethane foam separately under pressure towards the hollow space of the second cavity and mixing both components at the inlet of the second cavity with using of nozzles. Each pair of the component A and the component B is being supplied in such a way that the closed- cell foam and the open cell foam is obtained in the interior space of the particular cavity of the block and not before.

Preferably, filling the first cavity with the component A and B for closed-cell polyurethane foam to obtain the foam of density range from 25 to 60 kg/m3 in the interior space of the block and filling the second cavity with the component A and B for producing open-cell polyurethane foam to obtain the foam of density range from 5 to 12 kg/m3 in the interior space of the block.

Preferably, A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

Preferably, a through-hole is being created within each of the side walls of the block in such a way that the through-hole is created on a length from 20% to 80% of the brick side wall length and the through-hole is being filled with polyurethane foam to form separation made of a polyurethane foam within the side wall of the block. Preferably, at least one pair of the tongue and groove joint is being formed within side wall of the block.

In accordance with the present invention, there is provided a building element for thermal insulation in a form of hollow block or the likes characterized in that, the interior space of the block is filled with insulating material and this is obtainable by the process that the known components A and B for producing polyurethane foam are being prepared, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound. The process comprising the step of heating the A and B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components separately under pressure towards the hollow space in the block that mixing both components at the inlet of the hollow space with using of nozzles. The components supplying is performed in such a way that polyurethane foam is obtained in the interior space of a hollow block and not before.

Preferably, the interior space of the block is divided into two basic cavities each being hollow space of the block that separately adhere to each other longitudinally and the first cavity is a space limited by at least the front wall length of the block and the first cavity width amount to at least 3 mm wherein the second cavity is a space limited by at least back wall length of the block. The first cavity is being filled with known components A and B for producing a closed- cell polyurethane foam while the second cavity is being filled with known components A and B for producing an open-cell polyurethane foam, wherein supplying each pair of the component A and the component B in such a way that the closed-cell foam and the open cell foam is obtained in the interior space of the particular cavity of the block.

Preferably, a building concrete block or a clay building block or a perlite block is used as a type of the block. Preferably, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

Preferably, the polyurethane foam components are being supplied towards the hollow space in the block with injecting nozzle at pressure value at the outlet of the nozzle of at least 3.0 MPa.

Preferably, a through-hole is created within each of the side wall of the block in such a way that the through-hole has a length from 20% to 80% of the block side wall length and the through-hole is being filled with polyurethane foam to form separation made of a polyurethane foam in the side wall of the block.

Preferably, at least one pair of the tongue and groove joint is formed within side wall of the block.

According to further embodiment of the invention there is provided method for filling cavity of a building element and a building element for insulating in a form of hollow block or the likes filled with insulating material and the element is obtainable by this method. The methods comprising the step of preparing a spatial shaped mould such that the sizes of the mould are adjusted to the interior space sizes of the block cavity, wherein in case of space of a cavity is shaped of any polyhedron in cross-section, the internal length of the mould and the internal width of the mould are larger in range from 1 % to 7% as compared to the length of the cavity and the width of the cavity respectively. In case of the of space of a cavity in cross-section is shaped circularly, the internal diameter of the mould is larger in range from 1% to 7% as compared to the diameter of the cavity. The height of the mould is, in the each case, equal or larger than the size of the height of the cavity. As the insulating material an open-cell polyurethane foam or and a closed-cell polyurethane foam is being prepared in such a way that filling the interior space of the mould with known component A comprising a polyol compound, a foaming agent and the known component B comprising isocyanate compound, and then removing the produced shaped profile of polyurethane foam from the mould and then compressing the profile until the size that enables to locate the profile inside the cavity of the block following supplying the profile into the cavity of the block. Preferably, the polyurethane foam profile is being compressed with use of the spatial outlet chamber, the chamber being opened from its bottom and its top and the outlet chamber shape is adjusted to the size of the cavity of the block in a way that enables to locate the outlet chamber inside the cavity of the block.

Preferably, the polyurethane foam profile is being supplied into the cavity of the block with use of a piston.

Preferably, an open-cell polyurethane foam of density range from 5 to 12 kg/m3 is being prepared as the insulating material.

Preferably, a closed-cell polyurethane foam of density range from 25 to 60 kg/m3 is being prepared as the insulating material.

Preferably, the polyurethane foam components are being supplied towards the interior space of the mould with an injecting nozzle at the pressure value at the outlet of the nozzle of at least 3.0 MPa.

The building element according the invention enables to provide a high level of thermal insulation of construction. Due to high insulation parameters of the building element there is no necessity of additional insulating of walls construction that are built with the element that influences on construction time and costs saving. The method according to the invention also significantly lower costs of manufacture of construction materials that provide thermal insulation. The invention also enables to lower costs of production of building materials and concurrently enables to obtain the construction material that is characterized with a high level parameters of insulation. The method also provides reducing of insulating foam wastes that occurs during building construction. In the known methods that base on polyurethane foam using to provide heat insulation, the polyurethane foam is provided directly on the construction wall, that enforces to equip the wall with a supporting frame that is subsequently filled with a foam in amount that is determined by the frame. The main drawback of this method is that the way of foam blowing does not provide constant foam delivery what lead to obtain a significant foam waste that is removed to level of the frame. Additionally, spraying walls with foam necessitate to employ a group of specialists equipped with professional devices that also increase the total costs. The building material according the invention, depending on building required thickness, provides the thermal conductivity ratio at the minimum of U=0,11 W/(m2*K) for a wall thickness of 50 cm, that means a very high level of thermal insulation. On account of high heat insulation parameters of the building material obtained with the method according the invention there is no necessity of additional insulating of wall being built of the building element that impact on construction time and costs saving.

The embodiments of the invention are described with examples and figures, wherein on fig. 1, 4, 7, 10, 12 the building element is shown on axonometric projection before being filled with insulating material, and on fig. 2, 5, 8 the different interior space and cavities configuration of the building element before being filled with insulating material are shown in view from above and on fig. 3, 6, 9, 11, 13 the building element is shown on axonometric projection after being filled with insulating material. The further embodiment of the invention, that the foam- shaped profile obtained from a mold is used, is shown on fig. 14 and 15, that schematically depict preparative steps of method for filling hollow space with the foam profile, on fig. 16, that schematically depicts the method of foam profile being placed into the output chamber, on fig. 17 that schematically depicts method of filling hollow building element with the foam profile using the chamber and the piston.

Example 1

A building pre-element in a form of concrete hollow block made of known components is prepared with known method, wherein, as shown on fig. 1 , the through-holes are made within the side walls of the block and each hole amounts to approximately 50 % of the wall length of the block, that equals 20 cm. The side walls of the block are defined as the walls of the block that the block adhere with to a subsequent block in a linear blocks arrangement in building construction. The interior space of the block is divided into several smaller cavities, that makes an hollow block space. The through-holes location within the side walls and also the number and the shape of the smaller cavities are optional, as shown on fig. 2. Tongue and groove joints are formed within the side walls of the block that enables the building element to be bonded quickly and precisely during construction building with no necessity of vertical welds to be used. The tongue part of the joint is formed within one of the side walls of the block wherein the groove part of the joint is formed within the wall that is opposite to the former one and the parts are located parallel to each other. The formation of the joint is obtained by a proper shape of molds used for hollow block forming. The joints of the block shortens time and limits costs of construction building in significant way due to necessity of vertical welds using exclusion.

Such obtained hollow block is placed into the auxiliary form - mold that prevents from uncontrolled expansion of a foam that is produced within the interior space of the block. The form also enables to form additional tongue and groove joints located within the made of foam separations that fill the side wall through holes that were made during block preparation. The additional joints enables to reduce a necessity to use additional connections, thermal bridges and improves building elements bonding to each other.

Furthermore, the known open-cell foam making components A and B are being prepared. The A component compounds are a polyol mix (oligoetherols and oligoesterols), known chemical accelerators, known stabilizers, known additives and foaming substances, for example: water, to produce an open-cell foam. The B component is isocyanate compound that contains aromatic isocyanates, for example: methylene diphenyl diisocyanate homologues or toluene diisocyanate homologues. The A and B components amounts are such selected to provide a polyurethane open-cell foam of density 9,4 kg/m3. The components are being heated with known method to 45°C.

The high pressure unit is used for supplying components A and B into the internal space of the hollow brick. The high pressure unit works at pressure range of 100 to 270 Bars and is equipped with pumps, warmed up hosepipes, pressure chamber and injector formed into a pistol that is equipped with two nozzles. The high pressure unit dispense the A and B components individually under high pressure through hosepipes to separate nozzles. Additionally, the warmed up hosepipes of the unit keep set temperature of the components.

After the suction hosepipes are mounted and the set value of temperature is reached, the components A and B are individually being supplied, are pumped and injected by the high pressure unit pumps. The relevant pressure to be gained by the high pressure unit is 150 Bars to deliver the components to the nozzles that are located at the other ends of the hosepipes. The process of the components streams mixing - conjunction takes place just at the outlets of the nozzles and at the inlet of interior space - inside each cavity of the block. For this purpose the injecting pistols are located directly above or inside the cavity of the block and then the components A and B are being supplied in such a way that both A and B streams are being mixed - conjugate at the inlet of the block cavity. It has been experimentally revealed that when the pressure at the outlet of the nozzle is lower than 3,0 MPa, that is 30 Bars, it can be insufficient to conjugate the polyurethane foam components with a preferred effects. The prepared hollow block is placed into the form and with the injecting pistol the foam components are being injected under pressure into the hollow block interior empty space. The value of the pressure at the outlets of the nozzles is approximately 60 Bars. The foaming reaction takes place when the components A and B conjugate and lasts approximately 4 seconds. The components A and B mixing occurs on the level of the outlets of the nozzles and the process is performed in such that enables to obtain the final product of the process, that is the foam, exactly inside the hollow block interior space - in each cavity. Each cavity in the block is being filled with foam in the same way. The whole process is performed in external temperature of 20°C and air humidity of 50%.

After the foam being produced inside the each of the cavities of the block, the filled with foam block, is removed from the form and the excess foam that grown over the level of the block is equated with the knife to the upper level of the block. Such obtained building element is shown on fig. 3.

The previously made through-holes within the side walls of the block after the process are being filled with foam, that constitutes the made of polyurethane foam separations of the side walls of the block. Such solution enables to obtain additional insulating space among the building elements that are to be placed in line during construction building. The space in the side walls filled with foam provide additional insulation barrier within two such foam created separations. The insulation barrier enables the direct junction of the building elements placed in line in construction building and reduce a necessity of thermal bridges to be used. This provision impacts on the quality of thermal insulation of the building construction, partition with its significant improve.

Moreover, in the embodiment, within the made of foam separation two pairs of the tongue and groove joint are being created, wherein the parts of the one pair joint, groove and tongue part are located in parallel at the opposite sides of the building element, as shown on fig. 3. The joint are obtained with shape of the form, that the hollow block before being filled with A and B components is placed into. The joint enables to bond the building elements in more precise, more tight and more monolithic way and influence on time shortening and costs reducing of construction building. The tongue and groove connection can be created in any part of the made of foam partial separations within walls and also more than one pair of the connections can be created within the separation.

Such obtained construction building element in a form of the homogeneously filled with foam hollow block is suitable to be used within building partition constructing, that requires high level of insulation providing. The construction materials can be used as building material of residential as well as industrial buildings.

The building elements that provide heat insulation are characterized with efficiency and simplicity of bonding during construction wall building. According to the embodiment of the invention, the building elements are bonded in a linear way by tongue and groove joints, that reduces the necessity of vertical welds using. Heat insulating mortar is used for horizontal bonding. The thickness of the mortar is determined by producer's recommendation. Vapor permeable external and internal plasters are used to building finishing.

The obtained building element is characterized with the following features: high level of warmth retention, lightness, high vapor permeability, low water absorption, high frost resistance. The polyurethane foam also provides antibacterial and fungicidal performance. The thermal conductivity ratio of the construction material is approximately U=0,15 W(m2*K) at building partition width of below 42 cm. The using of the building elements enables to lower costs of characterized with such high insulation parameters building partition constructing.

Example 2

The method of building element manufacture is performed in similar way as described in example 1 , except that structural clay brick or block is used and filling with polyurethane foam is performed with automatic injector equipped with several nozzles.

Structural hollow clay block is prepared with known in the art method and of known compounds and subsequently through-holes are created within each of the two side walls of the block amount to approximately 55 % of the wall length, that equals 25 cm. The interior space of the block is divided into few smaller cavities, that make an internal hollow space between walls. Then the structural clay block is placed into the form that prevents from uncontrolled expansion of a foam that are being produced inside the internal space of the block. The form also enables to shape foam within the side walls of the block making foam separations and additional to manufacture tongue and groove joints located within the created through-holes during block preparation.

Then the known components A and B that open cell polyurethane foam is obtained of are being prepared, as described in the example 1. The A and B components amounts are such selected to obtain a polyurethane open-cell foam of density 8,0 kg/m3. The components are being heated with known method to 50°C. The high pressure unit is used for the components A and B to be supplied into the interior space of the structural clay block. The high pressure unit works at pressure range of 100 to 270 Bars and is equipped with pumps, warmed up hosepipes, high pressure generation section and automatic injector equipped with several pairs of nozzles. The nozzles layout is adjusted to the structural clay block construction in a way that a minimum one pair of nozzles is being located above hollow space of one cavity in the block. The number of nozzles is relevant to number of cavities in order to supply the components into cavities and therefore fill each cavities of the block with the foam concurrently during one round of component supplying. The automatic injector optionally can be equipped with only one pair of nozzles. In this case the injector is programmed to automatically move toward subsequent cavities of the block and supply the components into further cavity. The high pressure unit provide A and B components individually under high pressure through hosepipes to separate nozzles. Additionally, the warmed up hosepipes of the unit keep set temperature of the components.

After the suction hosepipes are mounted and the set value of temperature is reached, the components A and B are individually drawn by the high pressure unit pumps. The relevant pressure to be gained by the high pressure unit is 150 Bars to properly deliver the components to the nozzles of the automatic injector that is located at the other ends of the hosepipes.

During the method, the automatic foam injector is located just above the block such that its nozzles are located inside the interior space or directly above the block cavity and then the streams of the components A and B are concurrently launched and both streams conjugate and the components are mixed at the outlets of the nozzles and the streams are supplied into the cavity.

The prepared structural clay block is being placed inside the form and with the equipped with nozzles automatic injector the foam components are being injected directly into the empty block cavities. The pressure value at the outlets of the nozzles is over 30 Bars, averagely 70 Bars. The components A and B mixing occurs at the inlet of the block cavity that enables to fill the interior hollow space of the block with homogenous foam produced inside the block. The entire process is being performed in external temperature of 18°C and air humidity of 45%. The building element to be used within building partition is characterized with described in example 1 similar qualities and application.

Example 3 The method of building element production is performed similar as described in the example 1. A pearlite hollow brick or block is being prepared with known in the art method and of known components and subsequently the through holes are made within each side walls of the block and the holes amount to 15 cm, that is 35 % of the block wall length.

As shown on the fig. 4 the internal space of the block comprises two basic and main cavities, separated hollow spaces, that adhere to each other in one side - with longer and inner wall of the block and the basic cavities are divided into smaller cavities. The number and shape of the smaller cavities can be optional, as shown on the fig. 5. The basic hollow spaces can also be undivided into smaller cavities. The front wall - external wall, and back wall - internal wall of the block is defined regarding the location of the block in construction building made of the building elements. The first basic cavity 1, divided into two smaller cavities, is limited and determined by the front block wall 3 length and from the other side by the partition block wall, compartment inside the block, that is located parallel to the front block wall 3 and separate the first main cavity 1 from the second main cavity 2. The first basic cavity 1 width is 15 mm. The second basic cavity 2, divided into smaller cavities, is limited and determined by the back wall 4 length and from the other side by the partition block wall that separates the second basic cavity 2 from the first basic cavity 1. The second basic cavity 2 width is 380 mm.

The first basic cavity 1 is divided into two smaller cavities and the second basic cavities 2 is divided into seven smaller cavities. Within the side walls 5 of the block tongue and groove joints are being formed that enables the building elements to be bonded each other quickly and precisely during construction building with no necessity of vertical welds to be used.

Then the prepared perlite block is being placed into the form that prevents from uncontrolled expansion of a foam that forms inside the block, in interior space. The form also enables to fill the through-hole created within each side walls of the block where additional tongue and groove joints are created within the produced foam separations that fill the side wall holes of the block that reduce a necessity of thermal bridges to be used.

The known open-cell and closed-cell foam making components A and B are subsequently being prepared. The A component compounds are a polyol mix (oligoetherols and oligoesterols), known chemical accelerators, known stabilizers, known additives and foaming substances, for example: water, to produce an open-cell and closed-cell foam. The B component is isocyanate compound that contains aromatic isocyanates, for example: methylene diphenyl diisocyanate homologues or toluene diisocyanate homologues. The A and B components amounts are such selected to provide a polyurethane open-cell foam of density 8,5 kg/m3 and polyurethane closed- cell foam of density 36 kg m3. The components are heated with known method to 55°C. The closed-cell foam is characterized with no vapor permeability and its thermal conductivity is λ=0,023 W/mK, whereas the open-cell foam is characterized with vapor permeability and its thermal conductivity is λ=0,034 W/mK.

The high pressure unit is used for the components A and B to be supplied into the interior space of the block, as described in example 1. To obtain open-cell and closed-cell polyurethane foam two separate high pressure units are used to make each type of the foam individually and separately. The method of supplying components can also be performed with a single unit, wherein it requires to change components for the another type of the foam after the previous type was obtained.

To the prepared perlite block placed inside the form the injecting pistol is being provided and then the closed-cell polyurethane foam components are being injected into the first basic cavity 1. The pressure value at the outlets of the nozzles of the injector is approximately 75 Bars. The both components conjugation occurs at the inlet of the block basic cavity 1 , its hollow space, in such a way that component mixing enables to fill the interior space of the block first cavity 1 with the closed-cell polyurethane foam being produced inside the block. Then the subsequent injecting pistol that is connected with a different high pressure unit is being approached to the block and then the open-cell polyurethane foam components are being injected into the second basic cavity, its hollow space. The pressure value at the outlets of the nozzles of the injector is similarly approximately 75 Bars. The both components conjugation occurs at the inlet of the second basic cavity 2 in such a way that mixing components enables to fill the internal space of the second basic cavity 2 with the open-cell polyurethane foam, being produced in the block. The entire process is performed in external temperature of 22°C and air humidity of 60%.

After the foam being obtained inside the each of the main and smaller cavities of the block, the filled with foam block is being removed from the form and the excess foam that grown over the level of the block is equated with the knife to the upper level of the block. Such obtained building element for thermal insulation is shown on fig. 6.

Such obtained building element is characterized with higher level of heat insulation in comparison to when merely open-cell polyurethane foam is used with its process of manufacture. Additionally a vapor permeability is limited, since closed-cell polyurethane foam is dense so is not penetrated by steam. The thermal conductivity ratio of the building element is approximately of U=0,13 W(m2*K) at its width of approximately 45 cm. Example 4

The method of manufacture a building element is performed similar as described in the example 1 , wherein the concrete hollow brick or block made of known components is being prepared with known in the art method as shown on fig. 7. The block comprises two shorter side walls and the front - external wall and the back - internal wall. The interior space of the block is the hollow space between walls of the block that is divided into smaller cavities. The shape and number of the cavities is optional as shown on fig. 8. Within the side walls tongue and groove joints are being formed that enables the building elements to be bonded quickly and precisely during construction building with no necessity of vertical welds to be used.

Then the known components A and B are being prepared, that open-cell polyurethane foam inside the interior space of the block is being obtained of. The density of the obtained open-cell polyurethane foam is 7,5 kg/m3. The components are being heated with known method to 60°C.

The high pressure unit is used for the foam components to be supplied into the interior space block as described in example 1. The pressure generated by the unit is 150 Bars. The foam components are being supplied into the block cavities under pressure in the way that the pressure at the outlets of the unit nozzles is approximately 85 Bars. The entire process is performed in external temperature of 24°C and air humidity of 35%.

After the foam being produced and obtained inside the each of the cavities of the block, the excess foam that grown over the level of the block is equated with the knife to the upper level of the block. Such obtained building element is shown on fig. 9.

The obtained building material is characterized with similar features as the building element described in the example 1, wile the warmth retention, which is quite lower in comparison to the element described in the example 1. The thermal conductivity ratio of the obtained element is U=0,17 W/(m2*K) at its width of approximately 45 cm.

Example 5

The method of manufacture of building element is performed similarly as described in the example 1 , wherein the A and B foam components are such selected to provide a polyurethane closed-cell foam of density 36 kg/m3 and its thermal conductivity of λ=0,023 W/mK.

The obtained building element is characterized with the thermal conductivity ratio of approximately U=0,12 W/(m2*K) at building partition width of below 42 cm. The building element is also characterized with increased humidity resistance, in connection with low absorbability of the closed-cell foam. The vapor permeability is also lowered.

Example 6

The method of building element production is performed similarly as described in the examples 1 and 4 wherein the concrete hollow brick or bock made of known components is being prepared with known method as shown on fig. 10 that comprises two side walls without any tongue and groove joints formed within. Then the block hollow space is being filled with foam components to obtain the polyurethane foam inside, as described in the examples 1 and 4. The obtained building element is shown on fig. 11. The not equipped with tongue and groove joints building elements linear bonding determines a necessity of vertical and horizontal mortar welds to be used. The thickness of the mortar is determined by producer's recommendation. The building elements are connected to each other in the way of bonding and the layer of mortar on each walls of the element is created.

Example 7

The method of building element production is performed in similar way as described in the example 1, wherein the concrete hollow brick or block is being prepared as shown on fig. 12. Then the block interior space is being filled with foam components that the polyurethane foam is produced inside the block, as described in the example 1. The obtained building element is shown on fig. 13. The not equipped with tongue and groove joints building elements linear bonding determines a necessity of vertical and horizontal mortar welds to be used and the thickness of the mortar layer is determined by producer's recommendation.

Example 8

In different embodiment of the invention, the concrete hollow block is being prepared with using of the form as before. The interior space of the block is the hollow space between walls that is divided into two smaller cavities 1, that are equal in size, as shown on fig. 14. The external sizes of the block measured from the outer edge including walls of the rectangular cuboid block are as follows: the length is 600 mm, the width is 500 mm and the height is 240 mm. The internal sizes of the one cavity, its hollow space formed between wall, are as follows: a'=250 mm, b'=450 mm and d'=240 mm. Then the mould 6 of rectangular cuboid shape is prepared. The shape and internal sizes of the mold 6 are adjusted to the shape and sizes of the block cavity 1. The one plane of the mold is mounted to be tippable, as shown on fig. 14. The internal sizes of the mould 6 - its hollow space - measured from inner edge walls are as follows: a=257 mm, b=463 mm and d=960 mm. The length size of the mold 6 is 3% larger compared to the length of the block cavity 1, the width size of the mould 6 is 3% larger compared to the width of the block cavity, the height size of the mould 6 is four time higher compared to the height of the block cavity 1 that enables to prepare at least four shapes made of foam - shaped profile 7 in form of casts 7 that the block cavity 1 are to be filled with. When the block cavities are equal in size, the only one mould is sufficient to be prepared. In case of different cavities sizes, moulds of individually fitted to each block cavities sizes to obtain inside each of the mould shaped profiles 7 made of polyurethane foam that are suitable and compatible to the block cavities to fill space of particular cavity after being compressed. The mould 6 is prepared of non-adhesive material, that prevents from polyurethane foam adhesion to it, e.g. is made of polietylen.

Then the injecting pistol 9 is being approached to the interior space of the mould 6 and the known foam components are being supplied by injected into the hollow space of the mould 6 to open-cell polyurethane foam of density from 9,4 kg/m3 being obtained inside of the mould, as shown on fig. 14.

The foam to be used as insulating material is made of the known components. The open-cell foam making components A and B are being prepared. The A component compounds comprises a polyol mix (oligoetherols and oligoesterols), known chemical accelerators, known stabilizers, known additives and foaming substances, for example: water, to produce an open-cell foam. The B component comprises isocyanate compound that contains aromatic isocyanates, for example: methylene diphenyl diisocyanate homologues or toluene diisocyanate homologues. The A and B components amounts are such selected to provide a polyurethane open-cell foam of density 9,4 kg/m3. The components are being heated with known method to 45°C. The high pressure unit is used for the components A and B to be supplied into the mould 6. The high pressure unit works at pressure range of 100 to 270 Bars and is equipped with pumps, warmed up hosepipes, pressure chamber and injector formed into a pistol 9 that is equipped with two nozzles. The high pressure unit dispense the A and B components individually under high pressure through hosepipes to separate nozzles. Additionally, the warmed up hosepipes of the unit keep set temperature of the components. After the suction hosepipes are mounted and the set value of temperature is reached, the components A and B are individually drawn by the high pressure unit pumps. The relevant pressure to be gained by the high pressure unit is 150 Bars to properly deliver the components to the nozzles that are located at the other ends of the hosepipes. On account of the rapidity of foaming reaction of A and B foam components the process of the components streams conjunction takes place just at the outlets of the nozzles and at the inlet of the internal space of made of polyethylene mould 6. Therefore tthe injecting pistol is being located inside or directly above the mould 6 and then the streams of the components A and B are launched and then both streams conjugate and components are mixed at the inlet of the internal space - cavity of the mould 6. It has been experimentally indicated that when the pressure at the outlet of the nozzle is higher than 3,0 MPa, that is 30 Bars, the effectiveness of the polyurethane foam components conjugation is the highest and the effects according the invention are most preferable.

The injecting pistol 9 is being approached to the prepared mould 6 and with the injecting pistol the foam components A and B are injected under high pressure into the internal space of the mould 6. The value of the pressure at the outlets of the nozzles is approximately 60 Bars. The foaming reaction takes place when the components A and B conjugate and lasts approximately 5 seconds. The components A and B conjugation occurs on the level of the outlets of the nozzles. The whole process is performed in external temperature of 20°C and air humidity of 50%.

The foam formation and growth take place inside the internal space of the mould 6 with the effect of the foam polyurethane shaped profile - cast 7 obtainment that shape is determined and adjusted to the space shape of block cavity 1.

Then the polyurethane shaped profile 7 is removed from the mould 6 that takes place manually or with removing devices using and then the part of the profile of the height size of d'=240 mm, that corresponds to the height of the block cavity, is cut off with the blade, as shown at fig. 14.

Then the spatial outlet chamber 8 in a form of ramming chamber 8 is prepared. With its use the foam polyurethane profile 7 is to be supplied by compressing - rammed into the block cavity 1 space. The outlet chamber 8 is internally hollow and its shape in its basic part is determined and adjusted to the block cavity lin a way that it is enabled to locate the outlet chamber 8 in its lower part inside the block cavity 1.

After foam being cut off the obtained shaped profile 7 is located inside the outlet chamber 8, as shown on fig. 16. To simplify the shaped profile location inside the block cavity 1, the outlet chamber 8 from its bottom and top is opened, wherein the upper part of the outlet chamber 8 is shaped of funnel with widening shape in its upper part that ends with bigger - wider opening 11. The height of the tunnel is 250 mm and the sizes measured of its internal space are 265 mm x 470 mm. The larger top opening 11 of the outlet chamber sizes corresponding to the part of the profile sizes are larger, that so the positioning of the shaped profile 7 inside the outlet chamber 8, in its bottom part, is simplified and ensues from being rammed deeper inside the ramming chamber. This is achieved as a result of the foam shaped profile being compressed gradually that is enabled by polyurethane foam flexibility. To position the shaped profile 7 to bottom part of the outlet chamber 8 the piston 10 is to be used. The piston 10 works with its movability within the entire internal space of the outlet chamber 8, as shown on fig. 16 and 17. The internal space walls of the outlet chamber 8 are smooth that simplifies the profile 7 locating into the block cavity 1. The entire process can be performed either manually or mechanically. The shaped foam made profile 7 is supplied into the cavity 1 by using outlet chamber 8. The outlet chamber 8 is being positioned above the block cavity 1 and then the outlet chamber 8 is being put in the internal space of the block cavity 1 and then profile 7 is positioned into the outlet chamber 8 through the larger top opening 11 with the piston 10 using, as shown on fig. 17. The piston is being entered to the ramming chamber 8 through its larger top opening 11, that enables to position profile 7 into the block cavity 1 and prevents from the profile 7 receding during being located into the block cavity 1. Then the outlet chamber 8 is being removed from the cavity 1 while the position of the piston 10 remains unchanged, that enables to extrude the shaped profile 7 from the outlet chamber and locate the profile inside the block cavity 1, as shown on fig. 17. The shaped profile 7 then expands inside the block cavity 1 and fills its space tightly.

To fill each of the block cavities with the shaped and made of foam profile 7 the method of supplying the profile into the hollow space of the block - the cavity with using outlet chamber, as described above is to be repeated.

Such obtained homogenously filled with foam building element is to be used within building partition constructing that provides high level of warmth retention. The obtained building elements can be used as building material of residential as well as industrial buildings. The building element obtained according the method is characterized with the following features: high level of warmth retention, lightness, high vapor permeability, low water absorption, high frost resistance. The polyurethane foam also provides antibacterial and fungicidal performance.

The using of the building material enables to lower costs of constructing that characterized with high insulation parameters building partition. Example 9

The method is performed as described in the example 8, while the perlite brick or block is being prepared and the internal space of the block comprises two cavities 1 that are equal in size and are shaped circularly in cross-section, as shown on fig. 15. The sizes of the external planes constituting the rectangular cuboid of the block are as follows: the length is 500 mm, the width is 400 mm and the height is 200 mm. The internal space of the cavity 1 is described by sizes as follows: the diameter c'=230mm and the height d'=200mm.

Then the mould 6 is being prepared. The shape and internal sizes of the mould are determined and adjusted to the shape and sizes of the block cavites 1, as shown on fig. 15. The internal sizes of the mould 6 are as follows: the diameter c=246 mm, the height d=1000 mm. The diameter c size of the mould is 7% larger than the diameter c' size of the block cavity 1 and the height d size of the mould is five times larger than height d' size of the block cavity 1.

When the block cavities are equal in size, the only one mould is sufficient to be prepared. Otherwise, it necessitates to prepare moulds of individually fitted to each block cavity internal sizes adjusted to each of the block cavity to obtain foam shaped profile that cavity is to be filled with in whole hollow space.

Then the injecting pistol 9 is being approached to the mould 6 and the closed-cell foam components are being injected into the internal space of the mould 6 to obtain the closed-cell polyurethane foam of density from 36 kg/m3 inside the internal space of the mould, as shown on fig. 15.

The method is performed in similar way as described in the example 1, wherein the pressure value at the outlets of the nozzles is approximately 90 Bars. The process of A and B foam components conjunction is performed in external temperature of 15°C and air humidity of 60%. Then the outlet chamber 8 is being prepared that the profile 7 is located into. The process is then similar as described in the example 8, except that the outlet chamber internal space is circularly shaped in cross-section that makes it compatible in shape to the block cavities.

Example 10

The method is performed in identical way as described in the example 8, except that a structural clay brick or block is prepared. The block internal between walls space comprises four block cavities 1 that are equal in size. The sizes of the external planes constituting the rectangular cuboid of the block are as follows: the width is 200 mm, the length is 400 mm and the height is 230 mm. The sizes of the internal planes that constitute the rectangular cuboid of the block cavity 1 are as follows: a'=85 mm, b'=100 mm and d'=230 mm.

Then the mold 6 is being prepared. The internal sizes of the mould 6 that correspond to the block cavity sizes are as follows: a=80,8 mm, b=101 mm and d=230 mm. The length and width sizes of the mould are 1% larger than sizes of corresponding to them block cavity and the height size of the mould corresponding to the height d' size of the block cavity 1 remains unchanged, so there is no necessity to cutting off the foam in order to obtain the shaped profile 7.

Then the injecting pistol 9 is being approached to the mold 6 and the closed-cell foam components are being injected into the internal space of the mould 6 to obtain the closed-cell polyurethane foam of density from 45 kg/m3 inside the internal space of the mould. The method is performed identically as described in the example 1 , wherein the pressure value at the outlets of the nozzles is approximately 70 Bars. The process of A and B foam components conjunction is performed in external temperature of 23°C and air humidity of 55%.

Then the obtained foam shaped profile 7 is removed from the mould 6 and the outlet chamber 8 is being prepared that the profile 7 is being located into. The process performance is identical as described in the example 8.

To fill each cavity of the block with the foamed produced and shaped profile 7, the obtained profile are located one by one into block cavities with the outlet chamber using.

Claims

Patent claims

1. Method of manufacturing a building element for thermal insulation during that the interior space of a hollow block or the likes is being filled with insulating material characterized in that, the known components A and B for producing an open-cell or a closed-cell polyurethane foam are being prepared, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound and then the method comprising the step of heating the A and B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components separately under pressure towards the hollow space in the block that mixing both components at the inlet of the hollow space with using of nozzles in such a way that an open-cell or the closed-cell polyurethane foam is obtained in the interior space of a hollow block.

2 The method according to claim 1 characterized in that, the interior space of the hollow block is being filled with polyurethane foam components to obtain an open-cell polyurethane foam of density range from 5 to 12 kg/m3.

3 The method according to claim 1 characterized in that, the interior space of the hollow block is being filled with polyurethane foam components to obtain a closed- cell polyurethane foam of density range from 25 to 60 kg/m3.

4. The method according to any of claims 1-3 characterized in that, a building concrete block or a clay building block or a perlite block is used as a type of the block.

5. The method according to any of claims 1 -4 characterized in that, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

6. The method according any of claims 1-5 characterized in that, the polyurethane foam components are being supplied towards the hollow space in the block with injecting nozzle at the pressure value at the outlet of the nozzle of at least 3.0 MPa.

7. The method according to any of claims 1-6 characterized in that, a through-hole is being created within each of the side wall of the block in such a way that the through- hole is created on a length from 20%» to 80% of the brick side wall length and then through-hole is being filled with polyurethane foam to form a separation made of a polyurethane foam in the side wall of the block.

8. The method according to any of claims 1-7 characterized in that, at least one pair of the tongue and groove joint is being formed within side wall of the block.

9. The method according to the claim 7 wherein, at least one pair of the tongue and groove joint is being formed within the created separation filled with polyurethane foam, wherein the first part of the joint is formed within the separation of the first side wall of the block and the second part of the joint is formed within the separation of the second side wall of the block while the tongue part and the groove part of the joint are located in a parallel and opposite relation to each other.

10. The method of manufacturing a building element for thermal insulation during that the interior space of a hollow block or the likes is being filled with insulating material characterized in that, the interior space of the block is being divided into two basic cavities each being hollow space of the block that separately adhere to each other longitudinally and the first cavity (1) is a space limited by at least the front wall (3) length of the block and the first cavity (1) width amount to at least 3 mm wherein the second cavity (2) is a space limited by at least back wall (4) length of the block, and then known components A and B are being prepared for producing an open-cell polyurethane foam and the known components A and B are being prepared for producing a closed-cell polyurethane foam, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound and then the method comprising the step of heating the A components and the B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components for producing a closed-cell polyurethane foam separately under pressure towards the hollow space of the first cavity (1) that mixing both components at the inlet of the first cavity (1) with using of nozzles and supplying each of the A and B components for producing an open-cell polyurethane foam separately under pressure towards the hollow space of the second cavity (2) and mixing both components at the inlet of the second cavity (2) with using of nozzles, wherein each pair of the component A and the component B is being provided in such a way that the closed-cell foam and the open cell foam is obtained in the interior space of the particular cavity of the block.

1 1. The method according to the claim 10 characterized in that, filling the first cavity (1) with the component A and B for closed-cell polyurethane foam to obtain the foam of density range from 25 to 60 kg/m3 in the interior space of the block and filling the second cavity (2) with the component A and B for producing open-cell polyurethane foam to obtain the foam of density range from 5 to 12 kg/m3 in the interior space of the block.

12. The method according to any of the claims 10-11 characterized in that, a building concrete block or a clay building block or a perlite block is used as a type of the block.

13. The method according to any of the claims 10-12 characterized in that, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

14. The method according to any of the claims 10-13 characterized in that, the polyurethane foam components are being supplied towards the hollow space in the block with injecting nozzle at the pressure value at the outlet of the nozzle of at least 3.0 MPa.

15. The method according to any of the claims 10-14 characterized in that, a through- hole is being created within each of the side walls of the block in such a way that the through-hole is created on a length from 20% to 80% of the brick side wall length and the through-hole is being filled with polyurethane foam to form separation made of a polyurethane foam within the side wall of the block.

16. The method according to any of the claims 10-15 characterized in that, at least one pair of the tongue and groove joint is being formed within side wall of the block.

17. The method according to the claim 15 wherein, at least one pair of the tongue and groove joint is being formed within the created separation filled with polyurethane foam, wherein the first part of the joint is formed within the separation of the first side wall of the block and the second part of the joint is formed within the separation of the second side wall of the block while the tongue part and the groove part of the joint are located in a parallel and opposite relation to each other.

18. Building element for thermal insulation in a form of hollow block or the likes comprising two side walls, the front wall and the back wall characterized in that, the interior space of the block is filled with insulating material and this is obtainable by the process that the known components A and B for producing polyurethane foam are being prepared, wherein the A component comprises a polyol compound, a foaming agent and the B component comprises isocyanate compound and then the process comprising the step of heating the A and B components to temperature of range from 15 to 93 °C and then supplying each of the A and B components separately under pressure towards the hollow space in the block that mixing both components at the inlet of the hollow space with using of nozzles in such a way that polyurethane foam is obtained in the interior space of a hollow block.

19. The element according to claim 18 characterized in that, the interior space of the hollow block is being filled with polyurethane foam components to obtain an open-cell polyurethane foam of density range from 5 to 12 kg/m3.

20. The element according to claim 18 characterized in that, the interior space of the hollow block is being filled with polyurethane foam components to obtain a closed- cell polyurethane foam of density range from 25 to 60 kg/ni3.

21. The element according to the claim 18 characterized in that, the interior space of the block is divided into two basic cavities each being hollow space of the block that separately adhere to each other longitudinally and the first cavity (1) is a space limited by at least the front wall (3) length of the block and the first cavity (1) width amount to at least 3 mm wherein the second cavity (2) is a space limited by at least back wall (4) length of the block, and the first cavity (1) is being filled with known components A and B for producing a closed-cell polyurethane foam while the second cavity (2) is being filled with known components A and B for producing an open-cell polyurethane foam, wherein supplying each pair of the component A and the component B in such a way that the closed-cell foam and the open cell foam is obtained in the interior space of the particular cavity of the block.

22. The element according to any of the claims 18-21 characterized in that, a building concrete block or a clay building block or a perlite block is used as a type of the block.

23. The element according to any of the claims 18-22 characterized in that, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

24. The element according to any of the claims 18-23 characterized in that, the polyurethane foam components are being supplied towards the hollow space in the block with injecting nozzle at pressure value at the outlet of the nozzle of at least 3.0 MPa.

25. The component according to any of the claims 18-24 characterized in that, a through-hole is created within each of the side wall of the block in such a way that the through-hole has a length from 20% to 80% of the block side wall length and the through-hole is being filled with polyurethane foam to form separation made of a polyurethane foam in the side wall of the block.

26. The component according to any of the claims 18-25 characterized in that, at least one pair of the tongue and groove joint is formed within side wall of the block.

27. The element according to the claim 25 wherein, at least one pair of the tongue and groove joint is being formed within the created separation filled with polyurethane foam, wherein the first part of the joint is formed within the separation of the first side wall of the block and the second part of the joint is formed within the separation of the second side wall of the block while the tongue part and the groove part of the joint are located in a parallel and opposite relation to each other.

28. Method for filling cavity of a building element during the method an interior space of a hollow block or the likes is being filled with insulating material, characterized in that the methods comprising the step of preparing a spatial shaped mould (6) such that the sizes of the mould are adjusted to the interior space sizes of the block cavity, wherein in case of space of a cavity is shaped of any polyhedron in cross-section, the internal length (a) of the mould (6) and the internal width (b) of the mould (6) are larger in range from 1% to 7% as compared to the length (a") of the cavity and the width (V) of the cavity respectively, while in case of the of space of a cavity in cross- section is shaped circularly, the internal diameter (c) of the mould (6) is larger in range from 1% to 7% as compared to the diameter (c') of the cavity and the height (d) of the mould (6) is, in the each case, equal or larger than the size of the height (d') of the cavity, and moreover as the insulating material an open-cell polyurethane foam or and a closed-cell polyurethane foam is being prepared in such a way that filling the interior space of the mould (6) with known component A comprising a polyol compound, a foaming agent and the known component B comprising isocyanate compound, and then removing the produced shaped profile (7) of polyurethane foam from the mould

(6) and then compressing the profile (7) until the size that enables to locate the profile

(7) inside the cavity of the block following supplying the profile (7) into the cavity of the block.

29. The method according to claim 28 characterized in that, the polyurethane foam profile (7) is being compressed with use of the spatial outlet chamber (8), the chamber being opened from its bottom and its top and the outlet chamber shape (8) is compatible to the size of the cavity of the block in a way that enables to locate the outlet chamber (8) inside the cavity of the block.

30. The method according to claim 29 characterized in that, the polyurethane foam profile (7) is being supplied into the cavity of the block with use of a piston (8).

31. The method according to claim 28 characterized in that, an open-cell polyurethane foam of density range from 5 to 12 kg/m3 is being prepared as the insulating material.

32. The method according to the claim 28 characterized in that, a closed-cell polyurethane foam of density range from 25 to 60 kg/m3 is being prepared as the insulating material.

33. The method according to the claim 28 characterized in that, a building concrete block or a clay building block or a perlite block is used as a type of the block.

34. The method according to the claim 28 characterized in that, the A and B components mixing is performed in temperature of a range from -5 to 90°C and air humidity not exceeding 75%.

35. The method according to the claim 28 characterized in that, the polyurethane foam components are being supplied towards the interior space of the mould (6) with an injecting nozzle at the pressure value at the outlet of the nozzle of at least 3.0 MPa.

36. Building element for insulating in a form of hollow block or the likes filled with insulating material characterized in that, the interior space of the block is filled with polyurethane foam as the insulating material and the element is obtainable by the method in according to any of the claims 28-35.