ZA200300519B

ZA200300519B - Method and installation for continously producing components.

Info

Publication number: ZA200300519B
Application number: ZA200300519A
Authority: ZA
Inventors: Klaus Ritter
Original assignee: Evg Entwicklung Verwert Ges
Priority date: 2001-06-13
Filing date: 2003-01-20
Publication date: 2003-11-07
Also published as: EP1395378A1; BR0205600A; PL206047B1; EP1395378B1; ATE480346T1; PL358813A1; WO2002100569A1; DE50214647D1; BR0205600B1

Abstract

The invention relates to a method and device for continuously producing components (B), whereby two wire mesh mats (M, M') are placed in a parallel position at a distance from one another that corresponds to the desired thickness of the component (B). In order to form an insulating body (W) of the component, a plate (I, I1, I1', I2, I2') made of a heat-insulating material is inserted into the space between the parallel wire mesh mats while being situated at a distance from each wire mesh mat. In addition, a number of connecting wires (S, S') are, at the same time, inserted into the space between the wire mesh mats whereby passing through at least one of the two wire mesh mats. These connecting wires start from at least one side while running in a diagonal manner that alternates in opposite directions and in planes extending perpendicular to the planes of the wire mesh mats. The free ends of the connecting wires are pushed through the insulating body, whereby each connecting wire comes to rest near a wire (L, L', L1, L1'; Q, Q', Q1, Q1') of both wire mesh mats, and the connecting wires are welded to these wires. The ends of the connecting wires projecting beyond the wires are then cut off.

Description

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The invention concerns a method and an apparatus for the continuous manufacture of structural members which consist of two parallel, flat wire mesh mats consisting of ® longitudinal and transverse wires intersecting with each other and welded together at the points of intersection, straight bridge wires which hold the wire mesh mats at a predetermined distance from each other, and an insulating body which is arranged between the wire mesh mats and through which the bridge wires penetrate, a structural member manufactured by this method and with this apparatus, a method for encasing the structural member, and a method for manufacturing a prefabricated element from cast concrete.

From AT-C 372 886 are known a method and an apparatus for manufacturing a structural member of this kind. In this apparatus, first two wire mesh webs are brought into a parallel position at a distance from each other corresponding to the desired thickness of the structural member to be manufactured. In the gap between the wire mesh webs and at a distance from each wire mesh web is inserted an insulating panel. From wire supply reels, several bridge wires are passed in vertical rows one above the other from the side through one of the two wire mesh webs into the gap between the wire mesh webs and the insulating panel, in such a way that each bridge wire with its ends comes to lie each close to a mesh wire of the two wire mesh webs. The front ends of the bridge wires are welded to the corresponding mesh wires of one wire mesh web, and the bridge wires are cut off from the wire supply. In a subsequent working step, in a further bridge wire welding device the cut-off ends of the bridge wires are welded to the corresponding mesh wires of the other wire mesh web. In

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Q 2a subsequent working step the portions of the bridge wires protruding laterally from the wire mesh webs are cut off by trimming shears. Finally the structural members of ® corresponding length are cut off. A disadvantage with the known apparatus is that the cutting devices for cutting through the wire mesh webs of the already finished

Structural member at the end of the production line are extremely elaborate.

It is the object of the invention to provide a method and an apparatus of the kind provided hereinbefore which avoids the disadvantages of the known apparatus and makes it possible in a continuous manufacturing process to manufacture structural members of different construction, in particular with different arrangements of the bridge wires and rows of bridge wires, different types of wire mesh mats and insulating bodies. It is further the object ; of the invention to provide a method and an apparatus which makes it possible to use selectively prefabricated wire mesh mats and wire mesh webs for manufacturing the structural member. It is a further object of the invention to provide a structural member which can be made versatile in its properties and its construction such that it is optimally adapted to the desired static requirements in use _ and can be encased in a concrete shell on each side. It is a further object of the invention to provide a method for manufacturing a prefabricated element which makes it possible in a simple manner to manufacture a prefabricated element by means of the structural member and to adapt the dimensions of the prefabricated element to different static requirements.

The method according to the invention has the characteristics that two wire mesh mats are brought into a

Q 3 parallel position at a distance from each other corresponding to the desired thickness of the structural member, that to form the insulating body of the structural ® member a panel of heat-insulating material is introduced into the gap between the parallel wire mesh mats and at a distance from each wire mesh mat, that simultaneously several bridge wires are introduced from at least one side alternately in opposite directions obliquely in planes which run perpendicularly to the planes of the wire mesh mats and in which a reinforcement of the structural member is desired, through at least one of the two wire mesh mats into the gap between the wire mesh mats in such a way that the free ends of the bridge wires are pushed through the insulating body and each bridge wire comes to lie close to a wire of the two wire mesh mats, that the bridge wires are welded to these wires, and that the ends of the bridge wires protruding beyond the wires of the wire mesh mats are cut off.

An apparatus for carrying out the method according to the invention has the characteristics that on either side of a production channel is provided a curved directing device leading tangentially into the production channel, each for a wire mesh mat, that a guide device is provided for introducing insulating panels and/or an endless web of insulating material into the production channel, that the wire mesh mats can be advanced stepwise in the directing devices and in the production channel by means of a wire mesh mat conveying device, that an insulating body conveying device extending over the insulating body guide device and the production channel is provided for advancing, stepwise and synchronously with the wire mesh mats, at least partially dimensionally stable insulating

Q 4 bodies designed to fix the bridge wires, that within range of the wire mesh mat conveying device are provided several delivery and cutting devices for providing the insulating ® body with bridge wires, and several subsequent welding devices for simultaneously welding both ends of all bridge wires to corresponding longitudinal wires of the wire mesh mats, that the structural members can be delivered by means of a conveying device stepwise and successively to subsequent trimming devices for the protruding bridge wire ends and conveyed out of the production channel, and that all the conveying devices can be driven together, coupled to each other, by drive shafts.

Preferably on either side of the production channel is arranged an insertion device for taking an upright endless wire mesh web stepwise off at least one supply reel and for introducing the wire mesh webs into the directing devices, wherein in front of each directing device is provided a delivery device for delivering the wire mesh webs, a straightening device for straightening the wire mesh webs and a cutting device for cutting off wire mesh mats of predetermined length from the endless wire mesh webs, and wherein the wire mesh web delivery devices and the wire mesh web insertion devices together with all the conveying devices can be driven together, coupled to each other, by the drive shafts.

The subject of the invention is further a structural member consisting of two parallel, welded wire mesh mats, straight bridge wires which hold the wire mesh mats at a predetermined distance from each other and are connected at each end to the two wire mesh mats, and an insulating body which is arranged between the wire mesh mats and through which the bridge wires penetrate, wherein at least one of

Q 5 the wire mesh mats is constructed as a mesh reinforcing mat which exhibits a mechanical strength of the wires of the wire mesh mats corresponding to the minimum strength of the ® weld junctions conforming to the static requirements of the structural member, and has corresponding diameters and distances between the wires, wherein further the bridge wires are arranged in predetermined directions to the wire mesh mats and wherein the insulating body is held at a predetermined distance from each of the wire mesh mats.

Further characteristics and advantages of the invention are described in more detail below by practical examples with reference to the drawings. They show:

Fig. 1 a schematic top view of an apparatus according to the invention; Fig. 2 a schematic side view of a wire mesh mat conveying device; Figs. 3a and 3b different types of transport discs; Fig. 4 a schematic top view of a further embodiment of an apparatus according to the invention; Fig. 5 a further embodiment of delivery of the material to the apparatus according to the invention: Fig. 6 a further embodiment of delivery of the material to the apparatus according to the invention; Fig. 7 in an axonometric view a structural member according to the invention; Fig. 8 a further embodiment of a structural member according to the invention with through-holes in the insulating body, in a top view; Fig. 9 a section through the structural member as in Fig. 8 along the line II-II;

Fig. 10 a side view of the edge region of the structural member as in Fig. 7, seen in the direction of the transverse wires; Figs. 11 to 14 side views of structural members according to the invention with different embodiments of arrangement of the bridge wires within the structural member; Fig. 15 a side view of a structural o 6 member with asymmetrically arranged insulating body; Fig. 16 a side view of a structural member with additional edge bridge wires running perpendicularly to the wire mesh mats; ® Fig. 17 a side view of a structural member with wire mesh mats which protrude laterally beyond the insulating body at the edge of the structural member; Fig. 18 a side view of a structural member with an insulating body provided with cavities; Fig. 19 in a schematic perspective view a structural member with an outer shell and an inner shell of concrete; Fig. 20 a section through a structural member with a two-layer reinforcement, wherein an additional reinforcing mat is provided in the outer shell and the inner shell is made of concrete; Fig. 21 a section through a structural member with a two-layer reinforcement, wherein an additional reinforcing mat is provided in the inner shell and the outer shell is made of concrete; Fig. 22 a side view of a structural member with an insulating body whose outer surfaces are provided with recesses; Fig. 23 a side view of a structural member with an insulating body whose outer surfaces are provided with transverse grooves; and Fig. 24 a side view of a structural member with a plaster base mesh and with a release layer on an outer surface of the insulating body.

The apparatus according to the invention shown in Fig. 1 is used for manufacturing a structural member B consisting of two parallel, flat wire mesh mats M, M’ consisting of longitudinal and transverse wires L, L’ or Q,

Q’ intersecting with each other and welded together at the points of intersection, straight bridge wires S, S’ which hold the two wire mesh mats M, M’ at a predetermined distance from each other and which at each end are each welded to a wire of the two wire mesh mats M, M’, and an at oo least partially dimensionally stable insulating body W which is arranged between the wire mesh mats M, M’ and at a predetermined distance from them, for example an insulating @ panel I of synthetic material.

The apparatus has a main frame 1 on which a horizontal production channel 2, shown only schematically, is preferably arranged centrally. From two supply reels 3, 37, two upright wire mesh webs G and G’ are taken off in the direction of the arrows Pl and Pl’, wherein the distances between the longitudinal wires L, L’ or transverse wires Q,

Q" of each wire mesh web G, G', i.e. the so-called longitudinal wire and transverse wire spacing, as well as the width of each wire mesh web G, G’ can be freely selected within given ranges. :

Via a wire mesh web guide 4, 4’, each wire mesh web G,

G' passes into a straightening device 5, 5’ which in each case consists of several straightening rollers 6, 6’ offset from each other, which straighten each wire mesh web G, G'.

Each straightening device 5, 5’ comprises on its input side a wire mesh web delivery device 7, 7" which in each case consists of a carrier roller 8, 8’ and a driving roller 9, 9’ cooperating with the carrier roller 8, 8’, wherein each driving roller 9, 9’ can be either engaged with or disengaged from the carrier roller 8, 8’ by pivoting in the direction of the double arrow P2, P2’. The wire mesh web delivery devices 7, 7’ have the function of delivering the wire mesh webs G, G’ for further processing to subsequent wire mesh web insertion devices 10, 10’ in the direction of the arrows Pl, Pl’, or at the end of production conveying no longer needed remaining pieces of the wire mesh webs in a direction opposite the direction of the arrows Pl, P11’ out of the straightening devices 5, 5’.

® :

Each wire mesh web insertion device 10, 107 is pivotable in the direction of the double arrow P3, P3’ between a working position, in which it is engaged with the ® wire mesh web G, G’ to be inserted, and a rest position in which, disengaged from the wire mesh web G, G', it delivers it stepwise to wire mesh mat shears 11, 11” which essentially each comprise a cutter bar 12, 12’ and a blade bar 13, 13° and cut off wire mesh mats M, M’ of predetermined length from the endless wire mesh webs G, G".

The wire mesh mat shears 11, 117 in the example shown work so as to perform a separating cut and therefore cut off continuously succeeding wire mesh mats M, M’ from the wire mesh webs G, G’. Within the scope of the invention, however, it is also possible to design and control the wire mesh mat shears 11, 11’ in such a way that they perform a trimming cut on the longitudinal wires L, IL’ and in one or two cutting operations cut out of the wire mesh webs G, G’ a selectable section whose length in the direction of advance preferably corresponds to the transverse wire spacing or an integral multiple of the transverse wire spacing.

By slightly curved directing devices 14, 14’ which only elastically deform the straightened wire mesh mats M,

M’ and lead tangentially into opposite longitudinal sides of the production channel 2, and which for example consist of several arcuate strips arranged one above the other and are attached to the main frame 1 by means of brackets 15, 15’ and holders 16, 16’, the wire mesh mats M, MM’ are directed into the production channel 2 so as to move into a parallel position to each other there, with a distance between them which corresponds to the desired thickness of the structural member B to be manufactured. In the

J 9 production channel 2 the two wire mesh mats M, M’ are reliably guided across their whole width by means of distance-holder elements 17, 17’, shown only schematically, ® which for example consist of distance plates and several distance guides arranged one above the other in the vertical direction, and always kept precisely at this "predefined distance.

By means of a wire mesh mat conveying device 18 which essentially comprises two pairs of mutually opposed feed elements 19, 19’ and 20, 20’ arranged on both sides of the production channel 2, the two wire mesh mats M, M’ are conveyed stepwise in the directing devices 14, 14’ and along the production channel 2 in the direction of production P4 to the subsequent processing stations. The first pair of feed elements 19, 19’ is arranged in the parallel output region of the directing devices 14, 14’.

The distance between the first pair of feed elements 19, 19” and the wire mesh mat shears 11, 11’, and the distance between the two pairs of feed elements 19, 19’ and 20, 207, must be shorter than the shortest length of the wire mesh mats M, M’ intended for manufacturing the structural member

B, in order to ensure reliable further conveying of the wire mesh mats M, M’ by the wire mesh mat conveying device 18.

By a feeder device 21, individual insulating panels I are delivered in the arrow direction P5 to a guide device 22 which forms the input side of the production channel 2 and is attached to the main frame 1 by means of a fastening plate 23. The guide device 22 is designed in such a way that the insulating panel I is reliably guided both in the vertical direction and in its position relative to both wire mesh mats M, M’ and a predetermined distance from the

® 10 latter. The length and width of the insulating panel I preferably correspond to the length and width of the wire mesh mats M, M’.

In the input j f th id devi 22 th pu region o e guide evice , e insulating panel I is picked up by an insulating body conveying device 24 extending over the whole length of the production channel 2, and delivered stepwise synchronously with the wire mesh mats M, M’ to the subsequent processing : stations of the production plant.

Within the scope of the invention it is possible to deliver a web of insulating material K to the feeder device 21, instead of the individual insulating panels I previously cut to length, and by means of an insulating material cutting device 25 arranged in the output region of the guide device 22 to cut off insulating bodies W of predetermined length from the web of insulating material K.

Corresponding embodiments are described in more detail in

Figures 4 to 6.

On both sides of the production channel 2 behind the directing devices 14, 14’ is mounted in each case a bridge wire delivery and cutting device 26, 26’, with which several wires D, D’ are taken stepwise off wire supply reels 27, 27’ in the arrow direction P6, P6’ simultaneously from both sides of the production channel 2, straightened each by means of a conditioning device 28, 28’, introduced in a horizontal direction into the gap between the two wire mesh mats M, M’, pushed through the insulating body W, as by a nail, and cut off from the wire supply. It is made substantially easier to push them through the insulating body W by heating the tips of the bridge wires S, Ss’, wherein heating is effected for example by an inductively operating heating device.

Q 11

Within the scope of the invention it is possible to arrange all the bridge wire delivery and cutting devices 26, 26" on one side of the production channel 2 one behind ® the other in the direction of production.

Within the scope of the invention it is possible to deliver laterally to the production channel 2 bridge wires 5S, S' which have already been cut to length beforehand, in vertically extending rows R1 or R2 at selectable angles to the wire mesh mats M, M’. In this case too the tips of the bridge wires can be preheated by means of suitable heating devices.

Through the insulating body W extend several rows R1 or R2 each of several straight bridge wires S, S’ arranged in the vertical direction with mutual spacing one above the other. The bridge wires S, S’ are located with their two ends slightly laterally protruding in each case at the corresponding longitudinal wires L, L’ of the two wire mesh mats M, M’, to ensure reliable welding to the corresponding longitudinal wires L, L’ of the wire mesh mats M, M’. In the embodiment of the structural member shown, which corresponds to the embodiment of Fig. 10, the bridge wires

S, S’ run within a vertical row Rl or R2 in the same direction horizontally obliquely to the wire mesh mats M,

M’. In adjacent rows Rl, R2 the bridge wires S, S’ are inclined in opposite directions. Seen in the horizontal direction, the bridge wires S, S’ run in the form of horizontal lines H obliquely between opposed longitudinal wires L and L’ of the wire mesh mats M and M’. The respective angles of the bridge wires S, SS’ to the longitudinal wires L, L’ are selectable, wherein the direction of the bridge wires S, S$’ within a line 7 alternates so as to produce a trellis-like zigzag-shaped

® 12 arrangement of the bridge wires S, S’ within a line H. In the insulating body W, therefore, several parallel, horizontal lines H of bridge wires S, S’ are arranged one ® above the other in the vertical direction, i.e. the bridge wires S, S’ form in the insulating body W and hence also in

Che structural member B to be manufactured a matrix-like structure with horizontal lines H and vertical rows R1, RZ when the structural member B is upright.

The angle of insertion at which the bridge wires Ss, S' are introduced into the gap between the two wire mesh mats

M, M’ is adjustable by pivoting the bridge wire delivery and cutting device 26, 26’ in the direction of the double arrows P7, P77’. The material and construction of the insulating bodies W must be such that the insulating bodies

W fix the bridge wires S immovably in position within the insulating bodies W during subsequent further transport in the direction of production P4. The number, the angles of insertion and the vertical distances between the bridge wires S arranged in a row Rl or R2 in a vertical direction one above the other, as well as the horizontal distance between the bridge wire rows, are selected according to the static requirements of the structural member B.

In many applications it may be necessary to make the insulating body W of the structural member B of such hard materials that the bridge wires S, 8’ cannot penetrate through it without deforming it. For example, hard plastics such as polyurethane, lightweight concrete provided with expanded or foamable polystyrene as a lightweight aggregate, gypsum plasterboards or cement-bonded hardboards which contain plastic wastes, wood chips or wood shavings, mineral or vegetable fibrous materials, can be used here,

In these cases in front of each bridge wire delivery and

® 13 cutting device 26, 26’ is mounted a prepunching device 29, 29" shown schematically in Fig. 1. Each prepunching device 29, 29’ comprises several tools which are arranged one ® above the other in the vertical direction and which serve each to form a channel in the insulating body W for receiving a bridge wire S, S’ each and which are arranged on a common, pivotable stand. Here the stands of the prepunching devices 29, 29’ are permanently coupled to the associated bridge wire delivery and cutting device 26, 26’, and can be moved together with the latter in a direction towards the insulating body W of the structural member B and away from it and pivoted together with it in the direction of the double arrow P7, P7’.

Within the scope of the invention it is possible to design the prepunching devices 29, 29’ according to the device described in EP-B-398465. Here the advance movement of the prepunching devices 29, 29’ for forming the receiving channels for the bridge wires S, S’ takes place independently of the advance movement of the bridge wire delivery and cutting devices 26, 26’. Only the pivot movement of each stand of the prepunching devices 29, 29 for varying the angles of insertion of the bridge wires Ss,

S’ takes place synchronously with the pivot movement of the respectively associated bridge wire delivery and: cutting device 26, 26’ in the direction of the double arrows P7,

P77’.

The tools for forming the receiving channels for the bridge wires S, S’ can be designed as solid punching needles or hollow needles or as rotating drill bits, and comprise a wear-resistant, for example hardened tip. The punching or hollow needles are preferably preheatable at their tips to facilitate penetration of the insulating body

Ww.

The two wire mesh mats M, M’ are delivered by means of ® the second pair of feed elements 20, 20’ of the wire mesh mat conveying device 18 stepwise and synchronously with the insulating body W, which is advanced by means of the insulating body conveying device 24, together with the bridge wires Ss, S’ to subsequent bridge wire welding devices 30, 30’ in which the bridge wires S, S’ are welded each at one end by means of welding tongs 31, 31’ to the longitudinal wires L, L’ of the wire mesh mats M, M’. The bridge wire welding devices 30, 30’ are opposite and offset from each other on the outside of the two wire mesh mats M,

M’.

The structural member B, which is now dimensionally stable, is further conveyed stepwise by a subsequent structural member conveying device 32 which essentially comprises two pairs of conveying elements 33, 33’ and 34, 34" located opposite each other on both sides of the production channel 2.

The portions of the bridge wires S, S’ protruding laterally beyond the wire mesh mats M, M’ present a considerable risk of injury when handling the structural member B, hinder stacking of the structural members for transport, and must therefore be cut off so that the bridge wires S, S’ end if possible flush with the longitudinal wires L, L’. By means of the first pair of conveying elements 33, 33’, the structural member B is delivered to subsequent trimming devices 35, 35’ which are arranged offset on opposite sides of the production channel 2 and which cut off the bridge wire ends laterally protruding beyond the corresponding longitudinal wires L, L' of the

C 15 wire mesh mats M, M’ so that they are flush with the longitudinal wires L, L'.

Within the scope of the invention it is possible to ® divide the finished, trimmed structural member B in a horizontal direction into at least two, preferably equal- sized structural members, by means of horizontal cutting devices 36, 36’ mounted behind the trimming devices 35, 357 on both sides of the production channel 2. The horizontal cutting devices 36, 36’ are designed so as to be able to cut through both the transverse wires Q, QQ" of the wire mesh mats M, M’ and the insulating body W.

Within the scope of the invention it is also possible by means of the feeder device 21 to deliver individual insulating panels I cut to length and/or several vertically extending, endless webs of insulating material K in several paths running in a vertical direction one above the other, to the guide device 22.

Further, it 1s possible within the scope of the invention to divide the single-piece insulating panels I and/or the endless web of insulating material K in the insulating material web cutting device 25 by means of an additional cutting tool into at least two sections or partial webs running in a vertical direction one above the other, so that only the transverse wires Q, QO’ of the wire mesh mats M, M’ can be cut through in the horizontal cutting devices 36, 36’.

According to the invention, it is moreover possible in the insulating material web cutting device 25 during horizontal cutting of the insulating panel I or web of insulating material K not to cut right through it, but only to cut into it from both sides or from only one side of the insulating panel I or web of insulating material K, to such an extent that a bridge connecting the two portions remalns in the insulating body W. In the horizontal cutting devices 36, 36’ in this case only the transverse wires Q, Q" of the ® wire mesh mats M, M’ are cut through, and final division of the finished structural member B into two or more structural member portions is performed only on the construction site by breaking open the connecting bridge between the insulating bodies.

In order to keep the protruding transverse wire portions as short as possible when cutting through the structural member B and to avoid further trimming of the structural member portions, it is possible within the scope of the invention, as shown in Fig. 2, to select the distances between the two central longitudinal wires C, Cc’, between which the structural member B is cut through, correspondingly shorter than the remaining longitudinal wire spacing of the wire mesh mats M, M’.

The finished, trimmed structural member B is conveyed by means of the second pair of conveying elements 34, 34’ of the structural member conveying device 32 out of the production channel 2, and transferred to a device shown in

Fig. 4 for transporting away or stacking several structural members.

The distance between the second pair of feed elements 20, 20’ of the wire mesh mat conveying device 18 and the first pair of conveying elements 33, 33’ of the structural member conveying device 32, and the distance between the pairs of conveying elements 33, 33’ and 34, 34’, must always be shorter than the shortest length of the wire mesh mats M, M’ used to manufacture the structural member B, in order to ensure reliable further conveying of the wire mesh mats M, M’ between the wire mesh mat conveying device 18

® 17 and the structural member conveying device 32 as well as through the latter.

For continuous manufacture of the structural members ® B, it 1s absolutely necessary to deliver the two wire mesh webs G, GG’, the wire mesh mats M, M’ and the web of insulating material K or the individual insulating panels I reliably and without breakdown to the individual processing stations 11, 11’; 25; 26, 26’; 29, 29’; 30, 30’; 35, 35’; 36, 36’. To guarantee this, the wire mesh web insertion devices 10, 10’, the pairs of feed elements 19, 19’; 20, 20" of the wire mesh mat conveying device 18, the pairs of conveying elements 33, 337; 34, 34’ of the structural member conveying device 32 and the insulating body conveying device 24 are driven by a central main feed drive 37, wherein all the elements 19, 19’; 20, 20’; 33, 33’; 34, 34” and the wire mesh web insertion device 10, 10’ are connected to each other by means of articulated drive shafts 38, 38’. The feed steps take place cyclically because introduction of the bridge wires S, S’, welding of the bridge wires S, S’ to the wires of the wire mesh mat M,

M’ and trimming of the bridge wire end portions in each case take place while the wire mesh mats M, M’, the insulating body W or the structural member B are stationary. Here, the length of the feed steps can be selected according to the transverse wire spacing or an integral multiple of the transverse wire spacing.

By widening of the production channel 2 and corresponding individual or joint lateral displacement of the feed elements 19, 19’; 20, 20’, the conveying elements 33, 33’; 34, 34' and the elements of the processing stations 25; 26, 26’; 29, 29’; 30, 30"; 35, 35’; 36, 36’,

® 18 structural members B of varying predetermined width can be manufactured.

The insulating body conveying device 24 shown ® schematically in Fig. 2 comprises a conveying chain 39 which is driven by the main feed drive 37 in the arrow direction P8 and which defines the path of conveying the insulating bodies W within the production channel 2. The conveying chain 39 carries several carrier supports 40 which are each provided with a carrier 41. The carriers 41 are angled, hook-shaped or mandrel-like in order to make a reliable connection to the lower side of the insulating body W and so, during advance of the insulating body W, avold any slipping between the latter and the carrier supports 40.

During delivery of the insulating bodies W in several paths one above the other, the insulating body conveying device 24 comprises a further, upper conveying chain 39’ with corresponding carrier supports 40’ and carriers 41’ which engage on the upper side of the insulating body W of the uppermost web of insulating body.

The feed elements 19, 20 of the wire mesh mat conveying device 18, shown schematically in Fig. 2, comprise a shaft 42 which is inclined to the vertical and which is driven via a coupling 43 by an angular gear mechanism 44 and mounted in a thrust bearing 45. The angular gear mechanism 44 is driven via the drive shaft 38 by the main feed drive 37. Each shaft 42 is provided with several transport discs 46 which are arranged with mutual adjustable spacing and which are rotatable for adjustment on the shaft 42 and after adjustment are rigidly connected to the shaft 42 by means of a clamping element 47.

C 19

The transport discs 46 have, as shown in Fig. 3a, several mesh engagement recesses 48 of selectable depth distributed regularly over the circumference, so that _ flattened teeth 49 are formed. The number of mesh engagement recesses 48 is selected according to the transverse wire spacing of the wire mesh mats M, M’ such that the transverse wires Q, Q' of the wire mesh mats M, M’ are reliably picked up by the transport discs 46 and slip- free advance of the wire mesh mats M, M’" is ensured. As a result of the tilt of the shafts 42, the transport discs 46 of each feed element 19, 19’; 20, 20’ engage not just one, but several transverse wires Q, Q' of the wire mesh mats M,

M", so that the tensile force is distributed over several wires and the latter are thus subjected to not too great a load during advance of the wire mesh mats M, M’. The tilt of the shafts 42 moreover ensures continuous and slip-free further transport of the wire mesh mats M, M’ of successive structural members B, wherein the successive wire mesh mats in the butting region can have distances which arise for example when trimming the wire mesh mats M, M’" or when cutting sections out of the wire mesh webs G, G". : The conveying elements 33, 337; 34, 34" of the structural member conveying device 32 are constructed analogously to the feed elements 19, 19’; 20, 20’ of the wire mesh mat conveying device 18. Only the transport discs 46 comprise mesh engagement recesses 48 of less depth. The wire mesh web insertion devices 10, 10’ have essentially the same elements as the feed elements 19, 20 of the wire mesh mat conveying device 18 shown in Fig. 2. The only difference lies in that, as shown in Fig. 3b, the mesh engagement recesses 48 of the transport discs 50 are substantially deeper, so that they have pointed teeth 51.

J 20

This shape of the teeth 51 ensures that the teeth 51 engaging from the side in the unguided wire mesh web G, G’ reliably pick up the transverse wires Q of the wire mesh webs G, G’ and advance the wire mesh webs G, G’' without slip.

It is possible with the apparatus according to the invention to manufacture structural members B in which the wire mesh mats M, M’ have different constructions, i.e. different longitudinal wire spacings and/or transverse wire spacings as well as different diameters of the longitudinal wires and/or transverse wires. The different transverse wire spacings must however correspond to integral multiples and can be for example 50, 100 or 150 mm. A further restriction lies in that it must be ensured that the bridge wires S, S’ can be positioned in such a way that, in spite of these different wire spacings and wire diameters, they can reliably be welded to.the longitudinal wires of the two wire mesh mats M, M’.

It is possible with the apparatus according to the invention to manufacture structural members B in which one and/or both wire mesh mats M, M’ protrude beyond the insulating body W on one or both sides running parallel to the direction of production P4. To achieve this, either the carriers 41 are lifted or extended in such a way, or the conveying path of the conveying chain 39 is lifted in such a way, that the lower side surface of the insulating body Ww running parallel to the direction of production P4 is lifted accordingly, with the result that one and/or both wire mesh mats M, M’ form the desired protruding portion on this side. The conveying path of the upper conveying chain 39’ arranged on the upper side of the insulating bodies W o 21 must be lowered accordingly, or the carriers 41’ must be lowered or extended accordingly.

To manufacture structural members B in which the ® insulating bodies W protrude beyond the two wire mesh mats

M, M' on one or both sides running parallel to the direction of production P4, the conveying path of the lower conveying chain 39 is lowered in such a way, and if occasion arises the conveying path of the upper conveying chain 39’ is lifted in such a way, that the lower and if occasion arises the upper side surface of the insulating body W running parallel to the direction of production P4 is lowered or lifted accordingly, with the result that the insulating body W protrudes beyond the two wire mesh mats

M, M’ on one or both sides with the desired amount of protrusion.

Continuous manufacture of the structural members B by means of the apparatus according to the invention is preferably effected in such a way that the wire mesh mats

M, M’ of successive structural members B are separated from each other only by a negligibly narrow dividing gap between the longitudinal wires of successive wire mesh mats M, Mr, and also the correspondingly associated insulating bodies Ww of successive structural members B follow each other without significant gaps.

Within the scope of the invention, however, structural members B can also be manufactured in which one and/or both wire mesh mats M, M’ protrude beyond the insulating body w on one or both sides running perpendicularly to the direction of production P4. If one or both wire mesh mats

M, M’ are to protrude beyond the insulating body W on both sides, the insulating bodies W of adjacent structural members B are delivered by the feeder device 21 with

Correspondingly selected distances to the production channel 2 and there advanced with these mutual distances.

When using an endless web of insulating material K, upon ® cutting off the insulating bodies W a section corresponding to this distance must be cut out of the web K. The two dividing gaps between the wire mesh mats M, M’' of successive structural members B are here exactly opposite each other or laterally offset from each other.

To manufacture structural members B in which the insulating bodies W protrude beyond the two wire mesh mats

M, M’ on one or both sides running perpendicularly to the direction of production P4, the wire mesh mats M, M’ are advanced with a predetermined distance in ‘the production channel 2. To produce this selectable distance between the wire mesh mats M, M’ of successive structural members B, a section corresponding to this distance is cut out of the endless wire mesh webs G, G’ by the wire mesh mat shears 11, 11’ when producing the wire mesh mats M, M’. The amount of the distance is limited by the fact that it must be ensured that the gaps between the wire mesh mats M, M' of successive structural members B can be bridged by the obliquely extending shafts 42 of the wire mesh ‘mat conveying device 18 and of the structural member conveying device 32, to ensure slip-free advance of the wire mesh mats M, M’ of successive structural members B.

In case of large distances between adjacent bridge wire rows Rl and R2, within the scope of the invention two or more bridge wire welding devices 30 or 30’ per side surface can also be arranged one behind the other, seen in the direction of advance P4 of the wire mesh mats M, M’.

Here, the welding tong levers 66 or 67 and the welding electrodes 69 are designed in such a way that for every pair of welding tongs 31, 31° only one bridge wire S is welded to a corresponding longitudinal wire L, L'.

To increase the speed of production, moreover within ® the scope of the invention on each side surface of the structural member can be arranged several trimming devices one behind the other in the horizontal direction.

The apparatus shown in Fig. 4 consists, seen in the direction of production P4, of an insulating material delivery device 52, a wire mesh web delivery device 7, a wire mesh mat delivery device 53’, two bridge wire delivery or and cutting devices 26, 26’, two bridge wire welding devices 30, 30’, two trimming devices 35, 35’, a cutting device 25" for cutting through the web of insulating material K and a structural member transverse conveying device 54.

The insulating material delivery device 52 comprises an insertion device 55 which delivers the insulating panels

Il intended for forming the insulating body W of the structural member B, in the arrow direction P9 to the production line X-X of the apparatus. The insulating panels

Il are provided at one end face with a groove N and at the other, opposite end face with a tongue F, wherein groove’ and tongue are constructed in such a way and the insulating panels Il are arranged in such a way that the tongue of one insulating panel Il1 fits in form-locking and force-locking relationship in the groove of a subsequent insulating panel

I1’. The insertion device 55 consists of two work cylinders 56 whose piston rods are moved in the direction of the double arrow P10 and are provided at their end with a pressure plate 57. In the production line X-X is arranged a conveyor belt 58 which can be driven by means of a conveying drive 59 in the direction of production P4 and

® 24 advances the insulating panel Il in this direction along the production line X-X. Attached to a stand 60 is a transversely displaceable stop frame 61 which limits the ® delivery movement P9 of the insulating panels Il and fixes precisely the position of the insulating panels Il in the production line X-X. On the input side of the conveyor belt 58 1s arranged a feed device 62, for example a work cylinder. The piston rod of the work cylinder 62 is movable in the direction of the double arrow P4 and provided with a contract pressure plate 63 adapted to the grooved end face of the insulating panel Il. By means of the feed device 62, the insulating panel I1’ located on the conveyor belt 58 is additionally advanced in the direction of the arrow Pl in order to move the insulating panel Il’ relative to the already formed web of insulating material K and hence join the insulating panel Il’ in form-locking and force-locking relationship to the end of the web of insulating material K and produce an endless, coherent web of insulating material

K. Here, the tongue of the insulating panel Il’ engages in the groove of the terminal element of the web of insulating material K. The grooves and tongues are coordinated with each other in their design such that a form-locking and force-locking clamping joint is formed, which ensures both alignment of the insulating panels Il, Il’ to be joined and rigid joining thereof to each other.

The conveyor belt 58 is adjoined by the conveying : chain 39 which extends over the whole production line X-X and which can be driven in the direction of production P4 and moves the web of insulating material K in the production line X-X cyclically in the direction of production P4. The junction between the conveyor belt 58 and the beginning of the conveying chain 39 is defineq laterally by side plates 64, 64’ to avoid lateral yielding of the insulating panels Tl” upon joining adjacent insulating panels 1I1’ to form the web of insulating ® material K. The distance between the side plates 64, 64’ is adjustable to ensure guiding as close as possible even with different thicknesses of the insulating panels I1’. Within the scope of the invention it is possible to provide additional clamping elements which engage the web of insulating material K and which, upon joining the insulating panel Il’ to the already formed web of insulating material K, fix the latter in addition.

The wire mesh mat M is formed according to the embodiment described in Fig. 1 as follows. From a supply reel 3 an upright wire mesh web G is taken off in the arrow direction Pl by means of the wire mesh web insertion device : which essentially consists of a feed roller 10 which can be driven in the direction of the double arrow P12, and delivered to a straightening device 5. The straightening device 5 consists of two rows of straightening rollers 6 offset from each other and adjustable eccentric rollers 8.

By means of the feed rollers of the wire mesh web insertion device 10, the wire mesh web G is delivered stepwise to the wire mesh mat shears 11 which cut off wire mesh mats M of predetermined length from the endless wire mesh web G. The wire mesh mat shears 11 work in the embodiment shown in such a way that in a so-called Gassel cut they cut a selectable section out of the wire mesh web G, so that the wire mesh mats M delivered to the production line X-X follow each other at a distance. Within the scope of the invention, it is however also possible to design and control the wire mesh mat shears 11 in such a way that 3 separating cut or a trimming cut is performed.

The wire mesh mat M passes via the directing devices, not shown, into the production line X-X and is there delivered at a distance from and parallel to the web of ® insulating material K by means of two pairs of conveying elements 19, 19’; 20, 20’ which can be driven in the direction of the arrows P13, P13’, stepwise in the direction of production P4 along the production line X-X together with the web of insulating body K to the subsequent processing devices 26, 26’; 30, 30’ and 35, 357.

The delivery of already prefabricated wire mesh mats

M’ is effected by means of the wire mesh mat delivery device 53’ in the following manner: from a mat stack 657, by means of a transporter 66’ which is pivotable in the direction of the double arrow P14’, wire mesh mats M’ are removed successively and deposited in a holding rail 67. By means of an insertion device 68’, the wire mesh mats M’ are successively delivered in the arrow direction P15’ via a conditioning device 69’ to a feed roller 70’ which can be driven in the direction of the double arrow P16’. The insertion device 68’ consists for example of a work cylinder whose piston rod is movable in the direction of the double arrow P17’ and which is provided with a gripper 71 for picking up the wire mesh mat M’. The wire mesh mat conditioning device 69’ comprises conditioning rollers 72 offset from each other and eccentric rollers 73. The feed roller 70" successively pushes the wire mesh mats M’ stepwise into the production line X-X, where they are delivered at a distance from and parallel to the web of insulating material K and together with the latter by means of the pairs of conveying elements 19, 19’; 20, 20’ in the direction of production P4 stepwise along the production

® 27 line X-X to the subsequent processing devices 26, 26’; 30, 30" and 35, 357.

In the bridge wire delivery devices 26, 26’, several ® wires D, D’ are delivered simultaneously from both sides in the arrow directions P6é or P6’ and pushed as bridge wires

S, S" in a horizontal direction at a selectable angle through the holes of the wire mesh mats M, M’' and through the web of insulating material K, wherein the bridge wires

S, S’ abut with both their ends in each case against the corresponding wires L, L’ or Q, Q’ of the wire mesh mats M,

M’, slightly protruding laterally. The bridge wires S, S’ can within the scope of the invention be cut off from a wire supply by means of suitable shears or delivered as straightened rods already cut to length to the bridge wire delivery devices 26, 267.

By means of the pairs of conveying elements 19, 197; 20, 20’ the wire mesh mats M, M’ together with the web of insulating material K advanced by means of the conveying chain 39 and fitted with the bridge wires S, S$’ are delivered to the subsequent bridge wire welding devices 30, 30’ in which the bridge wires S, S’ are respectively welded to the corresponding wires L, L’ or Q, Q’ of the wire mesh mats M, M’. The mesh body H formed in this way together with web of insulating body K is delivered by means of two pairs of conveying elements 33, 33’; 34, 34’, which can be driven in. the arrow directions P18, P18’, to the subsequent trimming devices 35, 35’ in which the bridge wire portions protruding beyond the wires L, L’ or Q, Q’ of the wire mesh mats M, M’ are cut off flush.

By means of the pairs of conveying elements 33, 33’; 34, 34’, the mesh body H together with the web of insulating material K is delivered to the cutting device

@® 28 25". The cutting device 25’ cuts off the insulating body W in a selectable length from the web of insulating material

K, and comprises at least one cutting disc 75 which can be ® driven by means of a cutting drive 74. To increase the cutting output, a further cutting drive 74’ together with cutting disc 75 can be used. The cutting device 25’ is moved during cutting synchronously with the advance movements of the pairs of conveying elements 19, 197; 20, : 20" and 33, 33’; 34, 34’ in the direction of production P4 and, after cutting has taken place, returned to the starting position, wherein these movements take place in the direction of the double arrow P19. Movement into the cutting position and corresponding retraction from the cutting position take place in the direction of the double arrow P20. The length of the insulating body W can within the scope of the invention correspond exactly to the length of the wire mesh mats M, M’, so that the cutting device 25’ in a so-called Gassel cut must cut a corresponding section out of the web of insulating material K. It did however prove advantageous to let the insulating body Ww protrude slightly beyond the wire mesh mats M, M’, with the result that, when the structural members B are used, almost continuous insulation in the walls formed by the structural members B is achieved.

The finished structural member B is delivered along the production line X-X to a transverse conveyor 78 by a transporter 77 provided with a suitably designed gripper 76. The transporter 77 can for example consist of a work cylinder whose piston rod is movable in the direction of the double arrow P21. The transverse conveyor 78 pushes the finished structural members B in the arrow direction P22 out of the production line X-X. The transverse conveyor 78

® 29 consists for example of two work cylinders whose plston rods are movable in the direction of the double arrow P23 and each provided with a transfer plate 79. ® In Fig. 5 is shown schematically the input region of a further embodiment of an apparatus according to the invention. According to this embodiment, insulating panels

I2 which, compared with the insulating panels 1I1, Il’ described in Fig. 4, have plane end faces E are used.

Delivery of the insulating panels I2 to the production line

X-X onto the conveyor belt 58 is effected via the insertion device 55. To produce an endless web of insulating material

K, the insulating panel 1I2’ is joined to the web of insulating material K by hot-welding by means of a heating device 80. The heating device 80 essentially consists of a heating plate 81 and a heating transformer 82 which serves to heat up the heating plate 81.

The endless web of insulating material K is produced as follows. The insulating panel I2’ located on the conveyor belt 58 is advanced by means of the feed device 62 in the direction of the arrow P4 until the insulating panel

I2’ encounters the heating plate 81 which abuts against the terminal end face of the web of insulating material K. The heating plate 81 is then heated up by means of the heating transformer 82 until the butting end faces of the web of insulating material K and insulating panel I2' are softened. The heating plate 81 is then rapidly pulled out of the gap between the insulating panel I2’ and the web of insulating material K in the corresponding arrow direction of the double arrow P24, and the insulating panel I2’ is advanced slightly by means of the feed device 62 in the direction of production P4 in order to press the heated end faces against each other and so weld the insulating panel :

I27 to the web of insulating material K and so join them in form-locking and force-locking relationship. As the web of insulating material K during the joining operation is further conveyed by the conveyor belt 58 stepwise in time with the whole production plant in the direction of production P4, the heating device 80 during heating is also moved stepwise in the corresponding arrow direction of the double arrow P25 and, after removal of the heating plate 45, moved back into the starting position in the corresponding opposite direction of the double arrow P25.

Within the scope of the invention it is possible, as shown in Fig. 5, to arrange the cutting device 25 for _ cutting through the . web of insulating material K immediately behind the heating device 80 and before delivery of the wire mesh mats M, M’ to the production line

X-X. As the cutting device 25 is also, while the web of insulating material K is cut through, further conveyed by the conveying chain 39 stepwise in time with the whole production plant in the direction of production P4, the cutting device 25 during cutting is also moved stepwise in the corresponding arrow direction of the double arrow P19 and, at the end of cutting, moved back to the starting position in the corresponding opposite direction of the double arrow P19. The conveying chain 39 conveys the insulating bodies W cut off from the web of insulating material K in the direction of production P4 into the subsequent processing devices of the plant.

As the conveying chain 39 must not extend into the paths of movement of the heating device 80 and of the cutting device 25, the web of insulating material K in this region is supported by at least two support elements 83 which can be moved by means of a work cylinder 84 in the

® 31 direction of the double arrow P26 out of the path of movement of the heating device 80 and cutting device 25. 0) Within the scope of the invention it is possible, as shown in Fig. 5, to provide two supply reels 3, 3' with wire mesh webs G, G’ for producing the wire mesh mats M,

M’. The corresponding components here have the same reference numbers, which are in each case provided with or without apostrophe.

In Fig. 6 the input region of a further embodiment of an apparatus according to the invention is shown schematically. According to this embodiment, the insulating panels I2 already described in Fig. 5 are used likewise.

Delivery of the insulating panels I2 to the production line

X-X onto the conveyor belt 58 is effected via the insertion : device 55. To produce an endless web of insulating material

K, the insulating panel 1I2’ is joined to the web of insulating material K by gluing by means of a gluing device 85. The gluing device 85 comprises a spray nozzle 86 together with a reservoir which is filled with a suitable : glue. The glue must be suitable for gluing the material of the insulating panels I2 and have a drying time adapted to the speed of production in order to ensure reliable joining of the insulating panel I2’ to the web of insulating material K. The gluing device 85 is movable according to the double arrow P27 in a horizontal direction and in a vertical direction. To spray the glue onto the end face E of the insulating panel I2, the gluing device 85 is moved in these directions of movement. To accelerate application of the glue, within the scope of the invention several : gluing devices 85 can also be used simultaneously. Within the scope of the invention it is also possible to spray several insulating panels I2 with glue simultaneously. i

® 32

The endless web of insulating material K is produced in this embodiment in the following manner. Immediately ® before delivery of the insulating panel I2 to the production line X~X, an end face E of the insulating panel

I2 is provided with glue. The insulating panel I2 by means of the delivery device 52 is first advanced in the arrow direction P9 to the production line X-X and deposited on the conveyor belt 58. Next the insulating panel I2’ is advanced slightly by means of the feed device 62 in the direction of production P4, in order to press the glue-— coated end face of the insulating panel I2’ against the terminal end face of the insulating material K and so join the insulating panel I2’ to the web of insulating material

K. : : In Fig. 6 is shown a further embodiment of a cutting . device 25 for cutting off the insulating body W from the web of insulating material K. The cutting device 25 comprises a sliding carriage 87 which is slidable along a rail 88 in the direction of the double arrow P14, wherein movement in the direction of production P4 takes place synchronously with advance of the web of insulating material K. Attached to the sliding carriage 87 is a cutting wire 89 which is movable in the direction of the double arrow P28 transversely to the web of insulating material K and can be heated up by means of a heating transformer 90. To cut off the insulating body W from the web of insulating material K, the heated cutting wire 89 is : moved accordingly through the web of insulating material K and passes into the position shown in broken lines in Fig. 6. After cutting, the sliding carriage 87 together with cutting wire 89 is moved back into its starting position.

® 33

Within the scope of the invention it is possible to replace the cutting device 25’ shown in Fig. 4 by the ® cutting device described above, i.e. to arrange the cutting device described above after the trimming devices 35, 35’.

Within the scope of the invention it is possible, as shown in Fig. 6, to provide two mat stacks 65, 65’ with wire mesh mats M, M’. The corresponding components here have the same reference numbers which are in each case provided with or without apostrophe.

It goes without saying that the embodiments shown can be modified variously within the scope of the general concept of the invention, in particular with respect to the design and construction of the devices for joining the insulating panels to form an endless web of insulating material. Using suitable adhesives, both the end face of the insulating panel and the terminal end face of the web of insulating material can be provided with adhesive.

Furthermore it is possible within the scope of the : invention to provide one or both of the plane end faces of : the insulating panels to be joined, with a self-adhesive film. The film can already be applied when manufacturing the insulating panels and is appropriately protected by a removable film.

Furthermore it is possible within the scope of the invention to provide the tongued and grooved end faces of the insulating panels additionally with an adhesive to ensure reliable joining of the insulating panels.

The end faces of the insulating panels which are adjacent for forming the web of insulating material can also, within the scope of the invention, be provided with other clamping joint elements which cooperate in form-

C 34 locking and force-locking relationship and which are for example of dovetail construction.

Furthermore it is possible within the scope of the ® invention to use other cutting methods and devices for cutting off the insulating body from the web of insulating material. These methods and devices must be adapted to the material properties of the insulating materials and ensure that cutting produces edges as smooth as possible and the : material of the insulating body is not impaired in its properties, for example is melted. :

The structural member shown in an axonometric view in

Fig. 7 consists of an outer and an inner wire mesh mat M or

M’, which are arranged at a predetermined distance parallel to each other. Each wire mesh mat M or M’ consists of several longitudinal wires L or L‘’ and several transverse wires Q or Q’ which intersect with each other and are welded to each other at the points of intersection. The distances between the longitudinal wires L, L’ and between the transverse wires Q, Q' are selected according to the static requirements of the structural member. The distances are preferably selected of equal size, for example within the range of 50 to 150 mm, so that the respectively adjacent longitudinal and transverse wires form square holes. Within the scope of the invention the holes of the wire mesh mats M, M’ can also be rectangular and for example have short side lengths of 50 mm and long side lengths within the range from 75 to 100 mm.

The diameters of the longitudinal and transverse wires

L, L" or Q, Q’ can likewise be selected according to the static requirements and are preferably within the range from 2 to 6 mm. The surface of the wires L, L’; Q, Q’' of the wire mesh mats M, M’ can be smooth or ribbed within the scope of the invention. ® The two wire mesh mats M, M’ are joined to each other by several bridge wires S, S’ to form a dimensionally stable mesh body A. The bridge wires S, S’ are welded at their ends in each case to the wires of the two wire mesh mats M, M’, wherein within the scope of the invention the bridge wires S, S’ are welded either, as shown in Fig. 7, to the respective longitudinal wires L, L’ or to the transverse wires Q, Q’. The bridge wires M, M’ are arranged obliquely alternating in opposite directions, i.e. like a trellis, so that the mesh body is reinforced against shearing stress.

The distances between the bridge wires M, M’ and their distribution in the structural member depend on the static requirement of the structural member and are for example 200 mm along the longitudinal wires and 100 mm along the transverse wires. The distances between the bridge wires M,

M’ in the direction of the longitudinal wires L, L’ and transverse wires Q, Q’ are appropriately a multiple of the hole spacing. The diameter of the longitudinal wires L, L’ and transverse wires Q, Q' is preferably within the range from 3 to 7 mm, wherein, in the case of structural members with thin longitudinal and transverse wires, the diameter of the bridge wires S, S’ is preferably selected larger than the diameter of the longitudinal and transverse wires.

The three-dimensional mesh body A formed from the two wire mesh mats M, M’ and the bridge wires S, S$’ must not only be dimensionally stable, but, in its preferred use as a wall and/or ceiling element, also fulfil the function of a three-dimensional reinforcing element, i.e. take up shearing and compressive forces. Therefore both the longitudinal and transverse wires are welded to each other, as 1s usual for reinforcing mats, and the bridge wires 8S,

S’ are welded to the wires L, L’; QO, Q' of the wire mesh ® mats M, M’, maintaining a minimum strength of the weld junctions. In order to be able to fulfil the function of a three-dimensional reinforcing element, the wires L, L'; Q,

Q" of the wire mesh mats M, M’ and the bridge wires Ss, S’ must be made of suitable materials and have corresponding mechanical strength values, so that they can be used as reinforcing wires for the wire mesh mats M, M" to be used as mesh reinforcing mats or as reinforcing wires joining the two wire mesh mats M, M’.

In the gap between the wire mesh mats M, M’ at a predetermined distance from the wire mesh mats is arranged ~ an insulating body W whose outer surfaces 91 or 91’ run parallel to the wire mesh mats M, M’. The insulating body W serves for thermal insulation and sound insulation and is for example made of foam plastics such as polystyrene or polyurethane foam, rubber-based foam materials, lightweight concrete such as autoclaved or porous concrete, porous plastics, porous rubber-based materials, compressed slag, gypsum plasterboards, cement-bonded hardboards which are made of wood chips, Jute, r hemp and sisal fibres, rice husks, straw wastes, mineral and glass wool, corrugated cardboard, compressed waste paper, bonded brick chips, and melted recyclable plastic wastes. The insulating body W can also within the scope of the invention be made of bioplastics, for example algal foam material which is made from foamed algae or algal cellulose.

The insulating body W can be provided with predrilled holes for receiving the bridge wires S, SS’. The insulating body W can also be provided on one or both sides with a

® 37 plastic or aluminium layer serving as a vapour barrier. The position of the insulating body W in the structural member ® is fixed by the obliquely extending bridge wires S, 8’ which penetrate through the insulating body W.

The thickness of the insulating body W can be freely selected and is for example within the range from 20 to 200 mm. The distances between the insulating body W and the wire mesh mats M, M’ can also be freely selected and are for example within the range from 10 to 30 mm. The structural member can be made in any length and width, wherein on the basis of the manufacturing method a minimum length of 100 cm and standard widths of 60 cm, 100 cm, 110 cm, 120 cm proved to be advantageous.

In Fig. 8 in a top view and in Fig. 9 in a section along the line II-II is shown a further embodiment of a structural member according to the invention. In the insulating body W are formed several through-holes 92; 93, 93" which run perpendicularly and/or at a selectable angle in each case obliquely to the outer surfaces 91, 91’ of the ~ insulating body W. The through-holes 92; 93, 93’ are drilled in the insulating body W or punched out of it.

Within the scope of the invention it is also possible to make the through-holes . 92; 93, 937 already when manufacturing the insulating body W by suitable shaping of the forming tools. The directions of the obliquely extending through-holes 93, 93’ are selected such that, when using the structural member as a vertical wall, at least the through-holes 93, 93’ of one type run obliquely from top to bottom, wherein the directions run parallel to. the longitudinal wires L, VL’ and/or parallel to the transverse wires Q, Q’' of the wire mesh mats M, M’. The number, dimensions and distribution of all through-holes

® 38 92; 93, 93’ «can be freely selected. The number and dimensions should not be selected too large, in order not to impair the thermal insulation values of. the structural ® member too greatly. The number is for example between two and six per m®’. The shape of the through-holes 92; 93, 93’ can also be selected as desired and can be for example square, rectangular or round. With a round cross-section of the through-holes 92; 93, 93’, the diameters are preferably within the range from 50 to 100 mm. The distribution of the through-holes 92; 93, 93’ in the structural member can be regular or random within the scope of the invention, wherein to avoid resonance effects a random and asymmetrical distribution of the through-holes 92; 93, 93’ is advantageous.

As can be seen from the top view of the structural member shown in Fig. 9, in the case of the wire mesh mat M at the edge of the structural member B the longitudinal wires L and edge longitudinal wires Ll in each case end flush with the edge transverse wires Ql, and the transverse wires Q and edge transverse wires Ql in each case end flush with the edge longitudinal wires Ll. The same applies analogously to the wires L’, Ll’; Q', Ql’ of the other wire mesh mat M’.

In Fig. 10 is shown a side view of the structural member B in the direction of the transverse wire assembly.

The bridge wires S, S’ are in each case welded to the longitudinal wires L or L’ of the wire mesh mat M or M’.

Here, the bridge wires S running parallel in the transverse wire direction form a row Rl running perpendicularly to the plane of the drawing, and the corresponding bridge wires §’ form a further row R2 running perpendicularly to the plane of the drawing and running in the opposite direction

® 39 obliquely to the row Rl. The bridge wires S, §’ of different rows Rl lying in one plane form a bridge wire row

H which in Fig. 10 runs parallel to the plane of the ® drawing. During production of the structural member B in the apparatuses according to the invention, the rows R1, R2 run in a vertical direction perpendicularly to the direction of production P4, while the bridge wire rows H run in a horizontal direction parallel to the direction of production P4.

Figs. 11 and 12 respectively show embodiments with different angles between the bridge wires S, S’ and the corresponding longitudinal wires L, L’ of the wire mesh mats M, M’, wherein according to Fig. 11 different angles : within a row of bridge wires are also possible within a structural member.

Fig. 13 shows a structural member B in which in one row Rl the bridge wires S run in the same direction obliquely between the longitudinal wires L and L’ of the wire mesh mats M, M’, while in the next row R2 the bridge wires S’ shown in broken lines also run in the same direction obliquely, but with an opposite direction between the corresponding longitudinal wires IL, VL’, i.e. the structural member has several rows of bridge wires oblique in the same direction, with an alternating direction from one row to the next. Within the scope of the invention the rows of bridge wires oriented obliquely in the same : direction can also run between the transverse wires Q, Qf of the wire mesh mats M, M’. :

Fig. 14 shows a structural member B with bridge wires

S, SS’ running obliquely in opposite directions in each row

Rl, R2, wherein the distances between adjacent bridge wires in the row are selected such that the ends of the bridge

® 40 wires facing towards each other come as close as possible

Lo each other, so that if occasion arises two bridge wires ® can be welded jointly in a single operation to the corresponding mesh wire.

As Fig. 15 shows, the insulating body W can also be arranged asymmetrically to the two wire mesh mats M, M’.

Here, the diameters of the wires L’, Ll’; Q’, Ql’ of the wire mesh mat M’ further away from the insulating body W are advantageously larger than the diameters of the wires

L, Ll; Q, Ql of the wire mesh mat M closer to the insulating body W.

To reinforce the mesh body at its edges, according to

Fig. 16 additional edge bridge wires S1 running preferably perpendicularly to the wire mesh mats M, M’ and welded to the corresponding edge wires L1, L1"; Ql, Ql’ of the wire mesh mats M, M’ can be provided. The diameter of the edge bridge wires S1 is preferably equal to the diameter of the bridge wires S, S’. : In Fig. 17 is shown a structural member B according to the invention, of which the insulating body W at the side surfaces 94 which run parallel to the transverse wires OQ,

Q’" is not flush with the two wire mesh mats M, M’, but the latter protrude laterally beyond it. As a result of this embodiment, upon linking two identical structural members the insulating bodies of adjacent structural members can be arranged without a gap, while the wire mesh mats of the two © structural members overlap each other and so form a supporting lap joint. Analogously, the wire mesh mats M, M’ can protrude laterally beyond the side surfaces 94’ which run parallel to the longitudinal wires L, L’.

The insulating body W can also within the scope of the invention at all side surfaces 94, 94’ lie flush with the inner wire mesh mat M’ and protrude only beyond the wire mesh mat M which is the outer one in practical use.

Analogously, it is possible within the scope of the ® invention for the insulating body W at all side surfaces 94, 94" to lie flush with the outer wire mesh mat M and to protrude only beyond the wire mesh mat M’ which is the inner one in practical use.

One or both of the wire mesh mats M, M’ can also protrude laterally beyond the insulating body W at all side surfaces 94, 94’ thereof. In all embodiments any edge bridge wires S1 can be arranged so as to run outside the insulating body W or adjoin it flush laterally.

The longitudinal and transverse wires L, nL’, L1, Ll’;

Q, Q', Ql, Ql’ of the wire mesh mats M, M’ as well as the bridge wires S, S$’, S1 can have any cross-section. The cross-sections can be oval, rectangular, polygonal or square.

Fig. 18 shows a structural member B which comprises a two-part insulating body W’. Here, if necessary, the portions of the insulating body W’ can be adhered to each other at their contact surfaces. The two portions of the insulating body W’ for the purpose of saving material include cavities 95 which however can also be filled with other materials, for example pourable and free-flowing insulating materials such as wood and foam chips, sand, or plastic, rice or straw wastes. The insulating body W’ can also consist of several portions which can be joined together, for example have a multi-layer structure. It is further possible to provide a single-part insulating body w with cavities 95.

As shown schematically in Fig. 19, to the outer wire : mesh mat M intended to form the outside of the structural

C 42 member is applied an outer shell 96, for example of concrete, which adjoins the insulating body W, Wr’, encompasses the outer wire mesh mat M and together with the ® latter forms the supporting part of the fully concrete- covered structural member B’. The thickness of the outer shell 96 is selected according to the static as well as sound and heat requirements of the structural member B’ and is 20 to 200 mm, for example. If the structural member B is used as a ceiling element, then for static reasons the minimum thickness of the outer shell 96 must be 50 mm.

To the inner wire mesh mat M’ intended to form the inside of the structural member is applied an inner shell 97 which adjoins the insulating body W, W’, encompasses the inner wire mesh mat M’ and is made of concrete or mortar, for example. The thickness of the inner shell 97 is selected according to the static as well as sound and heat requirements of the structural member B’ and is 20 to 200 mm, for example. The two shells 96, 97 are preferably applied at the point of use of the structural member B’, for example sprayed on in a wet or dry process. The - statically required thickness of the outer shell 96 and inner shell 97 also determines the distance between the insulating body W, W’ and the wire mesh mats M, M’.

As the portions of the bridge wires S, S’ as well as, if occasion arises, the edge bridge wires S1 located in the : inner region of the structural member B’ are not covered with concrete and are therefore subject to corrosion, the bridge wires S, S$’ or S1 must be provided with an anti- : corrosion layer. This is preferably achieved by galvanising and/or plastic-coating the bridge wires S, S’, Sl. To allow welding of the bridge wires S, S’, S1 to the wires of the wire mesh mats M, M’, however, the plastic layer must not cover the end regions of the bridge wires S, S’ or edge bridge wires Sl. For reasons of cost, it proved advantage- ® ous to use galvanised wire already during manufacture of the mesh body A, at least for the bridge wires S, S’ Si.

The bridge wires 3S, SS’ S1 can also be made of stainless steel grades or other non~-corroding materials, e.g. aluminium alloys, wherein the latter must be capable of being connected to the wires of the wire mesh mats M, M’, preferably welded. Within the scope of the invention, the wires L, L’, L1, Ll’; Q, Q', Ql, Ql’ of all the wire mesh nats M, M’ or at least the wires L, Ll; Q, Ql of the outer wire mesh mat M can be provided with an anti-corrosion layer or made of stainless steel grades or other non- corroding materials. The anti-corrosion layer or the materials must be such that welding of the wires of the wire mesh mats M, M’ to the bridge wires S, S’ and to the edge bridge wires S1 1s possible without problems. The anti-corrosion layer can consist of a copper or zinc layer, for example. Within the scope of the invention it is possible in the case of the finished structural member B’ even before applying the outer and inner shells to provide at least the outer wire mesh mat M together with the regions of the bridge wires S, S$’ and edge bridge wires S1 protruding from the insulating body W, W’, with an anti- corrosion layer. This can be done for example by dipping the corresponding wire mesh mat M together with adjoining regions of the bridge wires S, S’ and edge bridge wires Si in a coating or galvanising bath.

For static reasons and/or to increase the sound insulation it may be necessary to provide the structural member B’ on at least one side of the structural member with a very thick concrete shell with a two-layer

® 44 reinforcement. In Fig. 20 is shown a detail of a structural member B’ with a very thick outer shell 96’ of concrete, ® wherein the outer shell 96’ is reinforced with an outer, additional reinforcing mat 98 of which the distance from the outer wire mesh mat M can be freely selected according to the static requirements of the structural member B’. The outer additional reinforcing mat 98 prevents cracking in the outer shell 96’ caused by temperature and shrinkage stresses.

The structural member B’ can also, for static reasons and/or to increase the sound insulation, be provided with a very thick inner shell a7’, wherein the latter is reinforced either only with an inner wire mesh mat M’ or, as Fig. 21 shows, with an inner wire mesh mat M’ and an inner, additional reinforcing mat 98’. The distance between the inner additional reinforcing mat 98’ and the inner wire mesh mat M’ can be freely selected according to the static requirements of the structural member B’. The diameters of the wires of the outer additional reinforcing mat 98 and/or of the inner additional reinforcing mat 98’ are preferably larger than the diameters of the wires of the two wire mesh mats M, M’ and are within the range from 3 to 7 mm, for example. If the thick inner shell 97’ is reinforced only with the inner wire mesh mat M’, the diameters of the wires

L’, L1'; Q’', Ql’ of the inner wire mesh mat M’ and of the bridge wires 5S, S’, S11 are preferably larger than the diameters of the mesh wires L, Ll; Q, Ql of the outer wire mesh mat M and are within the range from 5 to 6 mm, for example. This applies analogously in the event that the thick outer shell 96’ is reinforced only with the outer wire mesh mat M.

® 5

The inner wire mesh mat M’ and the inner additional reinforcing mat 98’ can be joined by several distance wires ® 99 which preferably run perpendicularly to the inner wire mesh mat M’ and inner additional reinforcing mat 98’ and of which the mutual lateral spacing can be freely selected.

The diameter of the distance wires 99 is preferably equal to the diameters of the wires of the wire mesh mats M, M’.

Within the scope of the invention, the outer additional reinforcing mat 98 and the outer wire mesh mat M can also be joined with distance wires which preferably run perpendicularly to the outer wire mesh mat M and outer additional reinforcing mat 98. These distance wires are arranged at selectable lateral distances from each other and have diameters which are preferably equal to the diameters of the wires of the two wire mesh mats M, M’.

The thick concrete shells 96’ and 97’ provided with two-layer reinforcement can also be cast from in-situ concrete at the point of use of the structural member B’, wherein the outer boundary of the concrete shells 96’, 97’ is formed by a shuttering element, not shown.

To improve the adhesion to the two outer surfaces 91, 91’ of the insulating body W, W’ facing towards the wire mesh mats M, M’ when spraying on the outer shell 96 and inner shell 97 made of concrete, and prevent the material from running off undesirably during application, the outer surfaces 91, 91’ of the insulating body W, W’ can be roughened. As shown in Fig. 22, the outer surfaces 91, 91’ can be provided with recesses 100 which are formed in the outer surfaces 91, 91’ of the insulating body W, W’ during manufacture of the structural member B, for example by means of gear wheels or rollers which carry spikes or knobs on their circumference.

® 4

Within the scope of the invention it is possible according to Fig. 23 to provide the insulating body Ww, W’ ® atl its outer surfaces 91, 91’ with transverse grooves 101 which run in a horizontal direction if the structural member is used as a wall element. The recesses 100 and the transverse grooves 101 can also within the scope of the invention already be produced during manufacture of the insulating body.

To improve adhesion of the outer concrete shell 96 to the insulating body W, W’, as shown in Fig. 24 there can be used a plaster base mesh 102 which rests on the outer surface 91, 91’ of the insulating body W, W’ and is fixed by the bridge wires S, S$’, S1 or the insulating body W, W’.

The plaster base mesh 102 consists for example of a welded or woven fine wire mesh with a mesh size of for example 10 to 25 mm and wire diameters within the range from 0.8 to 1 mm. The plaster base mesh 102 can also within the scope of the invention be made of expanded metal. Between the plaster base mesh 102 and the outer surface 91, 91’ of the insulating body W, W’ can be arranged an additional release layer 103 made of for example aluminium foil, impregnated building paper or cardboard, which simultaneously serves as a vapour barrier and is preferably joined to the plaster base mesh 102.

It goes without saying that the embodiments described can be modified variously within the scope of the general concept of the invention; in particular it is possible to apply the outer shell 96 and/or the inner shell 97 to the structural member already at the manufacturing works.

The insulating body W, W’ and the release layer 103 can be made of materials which are non-inflammable or not readily inflammable or be impregnated or provided with materials which make the insulating body W, W’ and release layer 103 non-inflammable or not readily inflammable. The ® insulating body W, W’ and the release layer 103 can moreover be provided with a coat of paint which is non- inflammable or not readily inflammable.

Within the scope of the invention it is possible to make a cast concrete prefabricated wall from several structural members. This manufacturing method is distinguished by the fact that several central structural members B are arranged each with their narrow sides butting adjacent to each other with a selectable distance between two shuttering elements and the gaps between the insulating bodies W, W’ of the structural members B and the shuttering elements are completely filled with concrete. Here, the concrete shells are cast in several operations, wherein between the individual operations the concrete must not harden fully.

The method is used to manufacture vertical prefabricated walls. Here, to form a vertical prefabricated wall several structural members B are arranged each butting adjacent to each other in vertical and horizontal directions, and the lower structural members B are each anchored stationarily in a floor slab, wherein adjacent structural members B in the horizontal direction are arranged in alignment in a straight line and/or along a curved line and/or at any angle to each other.

Claims

® 4 Patent claims

® 1. Method for the continuous manufacture of structural members which consist of two parallel, flat wire mesh mats consisting of longitudinal and transverse wires intersecting with each other and welded together at the points of intersection, straight bridge wires which hold the wire mesh mats at a predetermined distance from each other, and an insulating body which is arranged between the wire mesh mats and through which the bridge wires penetrate, characterised in that two wire mesh mats (M, M") are brought into a parallel position at a distance from each other corresponding to the desired thickness of the structural member (B), in that to form the insulating body (W) of the structural member (B) a panel (I, I1, 11’, 1I2, I2’) of heat-insulating material is introduced into the gap between the parallel wire mesh mats (M, M’) and at a distance from each wire mesh mat (M, M’), in that simultaneously several bridge wires (S, S’) are introduced from at least one side alternately in opposite directions obliquely in planes which run perpendicularly to the planes of the wire mesh mats (M, M’) and in which a reinforcement of the structural member (B) is desired, through at least one of the two wire mesh mats (M, M’) into the gap between the wire mesh mats (M, M’) in such a way that the free ends of the bridge wires (S, S’) are pushed through the insulating body (W) and each bridge wire (S; S$’) comes to lie close to a wire (L, L’, L1, Ll’; Q, Q', Ql, Ql’) of the two wire mesh mats (M, M’), in that the bridge wires (s, S’) are welded to these wires (L, L", L1, L1’; Q, 0’, Q1, Ql’), and in that the ends of the bridge wires (S, Sr)

® I” protruding beyond the wires (L, L', Ll, Ll’; Q, Q', O01, Ql") of the wire mesh mats (M, M’) are cut off.

® 2. Method according to claim 1, characterised in that to form the bridge wires (S, S’) several wires (D, D’) are taken Stepwise off wire supply reels (3; 37) simultaneously, straightened and, after welding to the wires (L, L', L1, L1’; Q, Q’, Ql, Ql’) of the wire mesh mats (M, M’), cut off from the wire supply (3, 37).

3. Method according to either of «claims 1 or 2, characterised in that to form the wire mesh mats (M, M’) at least two wire mesh webs (G, G’) are taken stepwise off wire supply reels (3, 3’), then straightened and cut off the wire mesh webs (G, G’) according to the desired length of the wire mesh mats (M, M’).

4. Method according to any of claims 1 to 3, characterised in that to form the insulating body (W) of the structural member (B) first an endless, coherent web of insulating material (K) is produced from individual, prefabricated insulating panels (Il, Il’, I2, I2’) and advanced, and in that the insulating body (W) is then cut off from the web of insulating material (K) in a selectable length.

5. Method according to claim 4, characterised in that the insulating panels (I1, Ii’, 12, I27) are conveyed individually and successively to the production line (X~X) and, to produce the web of insulating material (K), displaced relative to each other in their longitudinal direction (P4), with the result that the end faces (N, F; E) of the adjacent insulating panels (Il, Il’, I2, I2') are

® 50 joined to each other in form-locking and force-locking relationship to form the web of insulating material (K).

® 6. Method according to either of claims 4 or 5, characterised in that, to produce the endless, coherent web of insulating material (K), the insulating panels (Il, Il’) are joined together by their end faces (N, F) in form- locking and force-locking relationship by clamping.

: 7. Method according to any of claims 4 to 6, characterised in that insulating panels (I2, I2’) with plane end faces (E) are used, and to produce the endless, coherent web of insulating material (K) an adhesive is applied to at least one end face (E) of adjacent insulating panels (I2, I2’') or the end face (E) is provided with a self-adhesive film.

8. Method according to any of claims 4 to 6, characterised in that insulating panels (I2, I2’) with plane end faces (E) are used, and to produce the endless, coherent web of insulating material (K) the end face (E) of one insulating panel (I2’') and the terminal end face of the web of insulating material (K) are jointly heated and joined by welding.

9. Method according to any of claims 1 to 8, characterised in that at least the front end portions of the bridge wires (S, S’) are heated before being pushed through the insulating body (W).

10. Apparatus for carrying out the method according to any of claims 1 to 8, characterised in that on either side of ga production channel (2) is provided a curved directing

® 51 device (14, 14’) leading tangentially into the production channel (2), each for a wire mesh mat (M; M’), in that a [ guide device (22) is provided for introducing insulating panels (I) and/or an endless web of insulating material (XK) into the production channel (2), in that the wire mesh mats (M, M") can be advanced stepwise in the directing devices (14, 14’) and in the production channel (2) by means of a wire mesh mat conveying device (18), in that an insulating body conveying device (24) extending over the insulating body guide device (22) and the production channel (2) is provided for advancing, stepwise and synchronously with the " wire mesh mats (M, M’), at least partially dimensionally stable insulating bodies (W) designed to fix the bridge : wires (S, S’), in that within range of the wire mesh mat conveying device (18) are provided several delivery and cutting devices (26, 26’) for providing the insulating body (W) with bridge wires (S, 8S’), and several subsequent welding devices (30, 30’) for simultaneously welding both ends of all bridge wires (Ss, S7) to corresponding longitudinal wires (L, L1, L’, L1’) of the wire mesh mats (M, M’"), in that the structural members (B) can be delivered by means of a conveying device (32) stepwise and successively to subsequent trimming devices (35, 35’) for the protruding bridge wire ends and conveyed out of the production channel (2), and in that all the conveying devices (18, 24, 32) can be driven together, coupled to each other, by drive shafts (38, 38’).

11. Apparatus according to claim 10, characterised in that on either side of the production channel (2) is arranged an insertion device (10, 10’) for taking an upright, endless wire mesh web (G; G’) stepwise off at least one supply reel

@® 52 (3; 3") and for introducing the wire mesh webs (G, G’) into the directing devices (14, 14’), in that in front of each ® directing device (14; 14’) is provided a delivery device (7; 7") for delivering the wire mesh webs (G; G’), a straightening device (5; 5’) for straightening the wire mesh webs (G; G’') and a cutting device (11; 11’) for cutting off wire mesh mats (M, M’) of predetermined length from the endless wire mesh webs (G, G’), and in that the wire mesh web delivery devices (7, 7’) and the wire mesh web insertion devices (10, 10’) together with all the conveying devices (18, 24, 32) can be driven together, coupled to each other, by the drive shafts (38, 38’).

12. Apparatus according to either of claims 10 or 11, characterised in that the length of the feed steps of the wire mesh web insertion devices (10, 10’), of the wire mesh mat conveying device (18), of the structural member conveying device (32) and of the insulating body conveying device (24) corresponds to the shortest distance between the transverse wires (Q, Ql, Q", Ql’) of the wire mesh mats (M, M") or an integral multiple of this distance.

13. Apparatus according to any of claims 10 to 12, characterised in that the wire mesh web insertion devices (10, 10’), the wire mesh mat conveying device (18), the structural member conveying device (32) and the insulating body conveying device (24) can be driven synchronously by a common main feed drive (37). :

14. Apparatus according to any of claims 10 to 12, : characterised in that a feeder device (21) for at least single-lane delivery of insulating panels (I) cut to length

® 53 and/or of an endless web of insulating material (K) into the guide device (22) and in the output region of the guide ® device (22) a cutting device (25) for cutting off insulating bodies (W) of predetermined length from the web of insulating material (K) are provided.

15. Apparatus according to any of claims 10 to 14, characterised in that the insulating bodies (W) and/or the wire mesh mats (M, M’) of successive structural members (B) can be advanced along the production channel (2) at predetermined distances, wherein the insulating bodies (W) can be introduced by means of the feeder device (21) at predetermined distances into the production channel (2) or, when cutting off the insulating bodies (W) from the web of insulating material (K), sections of predetermined length can be cut out of the web of insulating material (K) by : means of the cutting device (25), and in that by means of the cutting device (11, 11’) when cutting off the wire mesh mats (M, M’) from the endless wire mesh webs (G, G") sections of predetermined length can be cut out of the wire i- mesh webs (G, G’).

16. Apparatus according to claims 10 to 15, characterised in that the wire mesh mat conveying device (18) and the structural member conveying device (32) each comprise at least two pairs of feed elements (19, 19’; 20, 20’) or conveying elements (33, 337; 34, 347), wherein the : individual elements of all pairs are located opposite each other on both sides of the production channel (2).

17. Apparatus according to claim 16, characterised in that each. feed element (19, 19’; 20, 20’), each conveying ;

® 54 element (33, 33’; 34, 34’) and each wire mesh web insertion device (10; 10’) comprises a shaft (42) inclined to the vertical direction with at least two transport discs (46, ® 50) provided with several mesh engagement recesses (48).

18. Apparatus according to any of claims 13 to 17, characterised in that the insulating body conveying device (24) comprises at least one conveying chain (39; 39’) which can be driven by the main feed drive (37) and extends over the whole length of the production channel (2), with several carriers (41; 417).

19. Apparatus according to claim 18, characterised in that the conveying path of the conveying chains (39, 39’) or the : carriers (41, 41’) can be lifted and lowered.

20. Apparatus according to any of claims 10 to 19, characterised in that the wire mesh web insertion devices (10, 10’) can be pivoted ihto the path of advance of the wire mesh webs (G, G’).

21. Apparatus according to any of claims 10 to 20, characterised in that on either side of the production channel (2) is arranged a bridge wire delivery and cutting device (26; 26’), and in that the bridge wire delivery and : cutting devices (26, 26’) are pivotable about a vertical axis for varying the angles of insertion of the bridge wires (S, SS’).

22. Apparatus according to any of claims 10 to 21, characterised in that in front of each bridge wire delivery and cutting device (26; 26’) is mounted a prepunching

® 55 device (29; 28’) for forming channels in the insulating body (W) for receiving bridge wires (S, 8’), wherein these ® prepunching devices (29, 29’) are movable in a direction towards the insulating body (W) and away from it and pivotable synchronously with the bridge wire delivery and cutting devices (26, 26’) to vary the angles of insertion of the bridge wires (S, S’).

23. Apparatus according to claim 22, characterised in that the prepunching devices (29, 29’) for forming the receiving channel comprise a punching tool with a heatable tip.

24. Apparatus according to any of claims 10 to 23, characterised in that for each side surface of the structural member (B) to be manufactured is provided at least one welding device (30, 30’) provided with several welding tongs (31, 31’) for simultaneously welding in each case one end of several straight bridge wires (S, S’) arranged with mutual spacing one above the other in at least one row (Rl; R2), to the horizontally extending longitudinal wires (IL, Ll; L’, Ll’) of a wire mesh mat (M; M’), wherein the welding tongs (31, 31’) are constructed as two-armed pivotable lower and upper welding tong levers cooperating in pairs, of which the ends facing towards the wire mesh mats (M; M’) and pivotable into the mesh mat planes comprise welding electrodes for welding at least one bridge wire (S; 8’) to a longitudinal wire (L, Ll; L’, L1') of the wire mesh mat (M; M’), wherein each welding device (30; 307) is adjustable perpendicularly and parallel relative to the side surfaces of the structural member (B).

@® 56

25. Apparatus according to any of claims 10 to 24, characterised in that for each side surface of the ® structural member (B) is provided at least one trimming device (35; 35’) for simultaneously cutting off at least two adjacent protruding bridge wire portions, which comprises at least one pivotable upper blade and one pivotable lower blade cooperating with the latter, wherein for each horizontal line (H) of bridge wires (S, S') provided in the structural member (B) there are provided an associated upper blade and an associated lower blade.

26. Apparatus according to claim 25, characterised in that each trimming device (35; 357) is adjustable perpendicularly and parallel relative to the side surfaces of the structural member (B).

27. Apparatus according to any of claims 10 to 26, characterised in that behind the trimming devices (35, 357) is mounted at least on one side of the production channel (2) a horizontal cutting device (36, 36’) for horizontally dividing the structural member (B) into at least two sections preferably of equal size.

28. Apparatus according to any of claims 10 to 27, characterised in that the insulating body cutting device (25, 25") comprises at least one cutting tool for cutting through the insulating body (W) and/or the endless web of insulating material (K) into at least two sections and/or partial webs arranged one above the other in the vertical direction. k

® 57

29. Apparatus according to any of claims 10 to 28, characterised in that, to adjust the width of the ® structural member (B) to be manufactured, at least the devices (14’, 15’, 16’, 17’, 19’, 20’, 26’, 30", 33’, 34’, 35'", 36’, 38’) arranged on one side of the production channel (2) are displaceable relative to the devices (14, 15, 16, 17, 19, 20, 26, 39, 30, 33, 34, 35, 36, 38) arranged on other side of the production channel (2).

30. Apparatus according to any of claims 10 to 29, characterised in that a feed device (62) for displacing insulating panels (Il, TI1’, I2, I2') relative to a web of insulating material (K) for the purpose of forming a form- : locking and force-locking connection between the insulating panels (I1, Il’, 12, 1I2’) and the web of insulating material (K), and a cutting device (25) displaceable parallel to the production line (X-X) for cutting off an insulating body (W) from the web of insulating material (K), are provided.

31. Apparatus according to any of claims 14 to 30, characterised in that to produce the web of insulating material (K) a heating plate (81) is provided, with which the end face (E) of an insulating panel (I2, I2’) and the terminal end face of the web of insulating material (K) can be heated together.

32. Apparatus according to any of «claims 14 to 30, characterised in that to produce the web of insulating material (K) at least one gluing device (85) is provided, which is movable in horizontal and vertical directions and

® 58 with which at least one end face (E) of adjacent insulating panels (I2, I2’) can be provided with an adhesive layer. ® 33. Apparatus according to any of claims 14 to 32, characterised in that the cutting device (25’) is arranged behind the trimming devices (35, 35’) in the direction of production.

34. Apparatus according to any of claims 14 to 33, characterised in that the cutting device (25) is arranged in front of the conveying chains (39, 397) of the insulating body conveying device (24) and in that in the region between the feed device (62) for the insulating panels (I, Il, Il’, I2, I2’) and the conveying chains (39, 39") for the insulating body (W) are provided support elements (83) movable into the path of advance of the web of insulating material (K).

35. Apparatus according to any of claims 14 to 34, characterised in that the cutting device (25, 257) comprises at least one drivable cutting disc (75) movable in horizontal and vertical directions.

36. Apparatus according to any of claims 14 to 34, characterised in that the cutting device (25, 257) comprises a cutting wire (89) which is displaceable transversely to the web of insulating material (K) and can be heated by means of a heating transformer (90).

37. Apparatus according to any of claims 30 to 36, characterised in that a transporter (66, 66’) is provided for the removal of wire mesh mats (M, M’) already cut to

® 59 length from at least one mat stack (65, 65’), and an insertion device (68; 68’) is provided for insertion of the wire mesh mats (M, M’) in a conditioning device (69; 69’), ® and a drivable feed roller (70; 70’) is provided for insertion of the straightened wire mesh mats (M, M’) in the production line (X-X), and in that all feed rollers (70; 70") with the conveying device (24) for the web of insulating material (K) and the insulating body (W), the conveying device (18) for the wire mesh mats (M, M’), the conveying device (32) for the mesh body (A) and the structural member (B) and if occasion arises with the wire mesh web delivery devices (7, 7’) and the wire mesh web insertion devices (10, 10’) can be driven together, coupled to each other, by the drive shafts (38, 387).

-38. Apparatus according to any of claims 10 to 37, characterised in that, for pushing the finished structural member (B) out of the production line (X-X), at the end of the production channel (2) is provided a transverse conveyor (78), wherein the finished structural member (B) is delivered by means of a transport device (77) along the production line (X-X) to the transverse conveyor (78).

39. Structural member manufactured by a method according to any of claims 1 to 9 by means of an apparatus according to any of claims 9 to 38,. consisting of two parallel, welded . wire mesh mats, straight bridge wires which hold the Wire mesh mats at a predetermined distance from each other and are connected at each end to the two wire mesh mats, and an insulating body which is arranged between the wire mesh mats and through which the bridge wires penetrate, characterised in that at least one of the wire mesh mats

@® 60 (M; M’) is constructed as a mesh reinforcing mat which exhibits a mechanical strength of the wires (L, 1’, L1, ® Li", Qo, Q', Ql, Ql’) of the wire mesh mats (M, M’) corresponding to the minimum strength of the weld junctions conforming to the static requirements of the structural member (B), and has corresponding diameters and distances between the wires (L, L', Li, 1", Q, Q', Ql, Ql’), in that the bridge wires (S, $8’; S1) are arranged in predetermined directions to the wire mesh mats (M, MM’) and in that the insulating body (W) is held at a predetermined distance from each of the wire mesh mats (M; M’).

40. Structural member according to claim 39, characterised in that the bridge wires (S, S’) are arranged alternately in opposite directions obliquely between the wires {L, L", Li, Ll’, Q, Q", Ql, Ql’) of the wire mesh mats (M, M’) like a trellis. :

41. Structural member according to claim 40, characterised in that the bridge wires (S, S’) between the wires (IL, L’, Li, Ll’, 9, Q', Q1, Q1’') of the wire mesh mats (M, M’) are arranged in rows (Rl; R2) with bridge wires (S; S;) inclined in the same direction within them, wherein the direction alternates from one row (Rl) to the next (R2).

42. Structural member according to any of claims 39 to 41, characterised in that the mesh body () formed from the wire mesh mats (M, M’) and the bridge wires (S, S$’) is reinforced at least at two opposite edges by edge bridge wires (Sl) preferably running perpendicularly to the wire mesh mats (M, M’) and welded to the mesh edge wires (). }

® 61

43. Structural member according to claim 42, characterised in that the bridge wires (S, S’) and the edge bridge wires ® (S1) end flush with the corresponding wires (L, L’, LI, Ll", Q, Q', 01, 01’) of the wire mesh mats (M, M’).

44. Structural member according to any of claims 39 to 43, characterised in that the wires (L, L’, L1, Ll’, Q, Q', Ql, Ql") at the edge of the wire mesh mats (M, M’) end flush with the respective edge wires (L1, Ll’; 01, Ql’).

45. Structural member according to any of claims 39 to 44, characterised in that at least the bridge wires (S, SS’) and/or the edge bridge wires (Sl) are provided with an anti-corrosion layer.

46. Structural member according to claim 45, characterised in that the anti-corrosion layer consists of a zinc layer and/or a plastic layer.

47. Structural member according to any of claims 39 to 4s, characterised in that the wires (L, L1, Q, Ql; L’, L1', OQ, Ql") at least of the outer wire mesh mat (M) are provided with an anti-corrosion layer.

48. Structural member according to claim 47, characterised in that the wires (L, L’, L1, Ll’, Q, Q’, Ql, Ql’) of the + wire mesh mats (M, M’) are copper-plated or galvanised. :

49. Structural member according to any of claims 39 to 4s, characterised in that at least the outer wire mesh mat (M) and the adjoining regions of the bridge wires (S, S’) and

® 62 edge bridge wires (S1) protruding from the insulating body (W) are provided jointly with an anti-corrosion layer. ® 50. Structural member according to claim 49, characterised in that the anti-corrosion layer is applied by dip coating Or spray coating.

51. Structural member according to any of claims 39 to 44, characterised in that at least the bridge wires (S, S$’) and the edge bridge wires (S1) of the structural member (B) are made of non-corroding materials that can be welded to the wires (L, L’, Ll, L1’, Q, Q', Ql, Ql’) of the wire mesh mats (M, M").

52. Structural member according to claim 51, characterised in that the bridge wires (S, S’) and the edge bridge wires (S81) are made of a stainless steel grade.

53. Structural member according to any of claims 39 to 46, characterised in that the wires (L, L1, Q, Q1; L’, L1', Qr, Ql’) of at least the outer wire mesh mat (M) are made of non-corroding materials that can be welded to the bridge : wires (S, S’) and the edge bridge wires (S1).

54. Structural member according to any of claims 39 to 53, characterised in that both wire mesh mats (M, M’) are constructed as mesh reinforcing mats, in that the bridge wires (S, 8S’; S81) are constructed as shear reinforcing elements and welded to the wires (L, L1, Q, Ql or L', Li’, Q", Ql’) of at least one of the wire mesh mats (M; M’) with a predetermined minimum weld junction strength.

@® 63

55. Structural member according to any of claims 39 to 54, characterised in that the wires (L, L’, Ll, L1’, Q, Q', Q1, ® Ql’) of the wire mesh mats (M, M’) form square holes of which the side lengths are preferably within the range from 50 to 100 mm.

56. Structural member according to any of claims 39 to 54, characterised in that the wires (L, L’, L1, L1’, Q, Q’, 01, Ql’) of the wire mesh mats (M, M’) form rectangular holes with short side lengths of preferably 50 mm and long side lengths of preferably 75 to 100 mm.

57. Structural member according to any of claims 39 to 56, characterised in that the distances between the bridge wires (S, SS’) in the direction of the longitudinal wires () and transverse wires () of the wire mesh mats (M, M’) are a multiple of the hole spacing, wherein the number of bridge wires (S, S’) is preferably 50 to 200 per m2.

58. Structural member according to any of claims 39 to 57, characterised in that the diameters of the wires (IL, L’, Ll, L1", Q, Q", Ql, Ql’) of the wire mesh mats (M, M’) are within the range from 2 to 6 mm.

59. Structural member according to any of claims 42 to 58, characterised in that the diameters of the bridge wires (S, S’}) and the edge bridge wires (Sl) are within the range from 3 to 7 mm, wherein the diameter of the edge bridge wires (Sl) 1s preferably equal to the diameter of the bridge wires (S, SS’).

® 64

60. Structural member according to any of claims 39 to 59, characterised in that the diameter of the bridge wires (S, ® S", S81) is larger than the diameter of the wires (L, L’, Li, Li", Q, Q', Ql, Ql’) of the wire mesh mats (M, M’).

61. Structural member according to any of claims 39 to 60, characterised in that the insulating body (W) is made of a dimensionally stable material.

62. Structural member according to any of claims 39 to 61, characterised in that the insulating body (W) contains several cavities (95).

63. Structural member according to any of claims 39 to 61, characterised in that the insulating body (W) consists of several portions (W’) joined together.

64. Structural member according to claim 63, characterised in that the portions of the insulating body (W’) encompass cavities (95).

65. Structural member according to any of claims 39 to 64, characterised in that the insulating body (W, W’') is made of a sound- and heat-insulating material.

66. Structural member according to any of claims 39 to 65, characterised in that the insulating body (W, W’) is made of materials which are non-inflammable or at least not readily inflammable or is rendered non-inflammable or at least not readily inflammable by impregnation and/or additives or is provided at least on its outer surfaces

® 65 (91, 91") with a coat of paint which is non-inflammable or at least not readily inflammable. ® 67. Structural member according to any of claims 39 to 66, characterised in that the insulating body (W, W’) is made of foam plastics, preferably polystyrene or polyurethane foam, rubber-based foam materials, lightweight concrete, preferably autoclaved or porous concrete, porous plastic, porous rubber-based materials, gypsum plasterboards, cement-bonded hardboards which are made of wood chips, jute, hemp or sisal fibres, rice husks, straw wastes, mineral or rock wool, bonded brick chips, or melted plastic wastes.

68. Structural member according to any of claims 39 to 67, characterised in that in a single-piece insulating body (W) between the outer surfaces (91, 91’) is formed at least one straight through-hole (92; 93, 93’).

69. Structural member according to claim 68, characterised in that the or at least one through-hole (92) runs perpendicularly to the outer surfaces (91, 91’) of the insulating body (W).

70. Structural member according to claim 68, characterised in that the or at least one through-hole (93, 93’) runs at a predetermined angle obliquely to the outer surfaces (91, 91") of the insulating body (W), wherein the through-hole (93, 93’) runs obliquely from top to bottom when the structural member (B) is used as a vertical wall element.

71. Structural member according to claim 70, characterised in that each oblique through-hole (93, 93’) runs parallel ® to the longitudinal wires (L, L1, L’, L1’) and/or parallel to the transverse wires (Q, Ql, Q', Ql’) of the wire mesh mats (M, MM’).

72. Structural member according to any of claims 68 to 71, characterised in that the insulating body (W) comprises two to six through-holes (92; 93, 093’) per m?, wherein the distribution of the through-holes (92; 93, 93’) in the structural member (B) is preferably random.

73. Structural member according to any of claims 68 to 72, characterised in that each through-hole (92; 93, 93’) has a round cross-section with a diameter within the range from 50 to 100 mm.

74. Structural member according to any of claims 39 to 73, characterised in that at least one of the two outer surfaces (91, 91’) of the insulating body (W, WW’) facing towards the wire mesh mats (M, M’) is roughened.

75. Structural member according to any of claims 39 to 74, : characterised in that in at least one outer surface (91; 91’) of the insulating body (W, W’) are formed several recesses (100).

76. Structural member according to claim 75, characterised in that in at least one outer surface (91; 91’) of the insulating body (W) are formed several transverse grooves (101) running horizontally in the installed state of the structural member (B).

® 67

77. Structural member according to any of claims 39 to 76, ® characterised in that at least one outer surface (91; 91’) of the insulating body (W, W’) is provided with a layer (103) serving as a vapour barrier, wherein the layer (103) 1s made of material which is non-inflammable or at least not readily inflammable or provided with a non-inflammable impregnation or with a non-inflammable coat of paint.

78. Structural member according to any of claims 39 to 77, characterised in that at least one outer surface (91, 91’) of the insulating body (W) is provided with a plaster base mesh (102).

79. Structural member according to any of claims 39 to 78, characterised in that the thickness of the insulating body (W, W') is within the range from 20 to 200 mm.

80. Structural member according to any of claims 39 to 79, characterised in that the insulating body (W, W’) is arranged centrally to the two wire mesh mats (M, M’), wherein the distance from each wire mesh mat (M; M") is preferably 10 to 30 mm.

81. Structural member according to any of claims 39 to 79, characterised in that the distance from the insulating body (W, W') to one wire mesh mat (M; M’) is greater than the distance from the insulating body (W, W’) to the other wire mesh mat (M'; M).

82. Structural member according to any of claims 39 to 81, characterised in that the diameters of the wires (L, L1, Q,

Ql; L", Ll’, Q", Ql’) of the wire mesh mat (M; M’) further away relative to the insulating body (W, W’) and of the ® bridge wires (S, S’) are larger than the diameters of the wires (L’, L1’, Q', Ql’; L, Ll, Q, Ql) of the wire mesh mat (M"; M) closer relative to the insulating body (W, W’).

83. Structural member according to any of claims 39 to 82, characterised in that at least one wire mesh mat (M; M’) of the insulating body (W, W’) protrudes laterally on at least one side surface (94; 94’) of the insulating body (W, W’).

84. Structural member according to any of claims 39 to 82, characterised in that the insulating body (W, W’) protrudes laterally beyond at least one wire mesh mat (M; M’) on at least one side surface (94; 94’) of the insulating body (W,

wr).

85. Structural member according to any of claims 39 to 84, characterised in that the wires (L, Ll, Q, Qi; L’, Ll’, Q', Ql’) of one or both wire mesh mats (M; M’) have a ribbed surface.

86. Method for encasing a structural member according to any of claims 39 to 85, characterised in that to the outer wire mesh mat (M) intended to form the outside of the structural member is applied a concrete outer shell (96, 96’) which adjoins the insulating body (W, W’), encompasses the outer wire mesh mat (M) and together with the latter forms the supporting part of the fully concrete-covered structural member (B’), and in that to the inner wire mesh mat (M’) intended to form the inside of the structural member is applied a concrete inner shell (97, 97’) which

® 69 adjoins the insulating body (W, W’), encompasses the inner wire mesh mat (M’) and together with the latter forms the ® supporting part of the fully concrete-covered structural : member (B’), and in that in this case, if any, each through-hole (92, 93, 93’) is filled with a concrete bridge which joins the concrete outer shell (96, 96’) and the concrete inner shell (97, 977) in force-locking relationship.

87. Structural member according to claim 86, characterised in that the inner shell (97, 97’) is made of concrete, plaster or mortar.

88. Structural member according to either of claims 86 or 87, characterised in that the outer shell (96’) is provided with an additional reinforcing mat (98) of which the distance from the outer wire mesh mat (M) can be selected according to the static requirements of the structural member (B").

89. Structural member according to any of claims 86 to 88, characterised in that the inner shell (97’) is provided with an inner additional reinforcing mat (98’) of which the distance from the inner wire mesh mat (M’) can be selected ’ according to the static requirements of the structural member (B’).

90. Structural member according to either of claims 88 or 89, characterised in that the diameters of the longitudinal and transverse wires of the outer and/or inner additional reinforcing mat (98; 98’) are larger than the diameters of the wires (L, L’, L1, Ll’, Q, Q', Ql, Ql’) of the wire mesh mats (M, M’'). ® 91. Structural member according to any of claims 88 to 90, characterised in that the inner additional reinforcing mat (98"7) is joined to the inner wire mesh mat (M’) and/or the outer additional reinforcing mat (98) is joined to the outer wire mesh mat (M) each by several distance wires (99), wherein the distance wires (99) are arranged with a selectable distance between them and preferably run perpendicularly to the wire mesh mats (M, M’) and the additional reinforcing mats (98, 98"), wherein their diameters are preferably equal to the diameters of the wires (L, L’, L1, L1’, Q, Q', O01, Ql’) of the wire mesh mats (M, M’).

92. Structural member according to any of claims 86 to 91, characterised in that the thickness of the outer shell (96, 96’) and/or inner shell (97, 97") is within the range from to 200 mm.

93. Method for manufacturing a prefabricated element from cast concrete with several central structural members according to any of claims 39 to 85, characterised in that several central structural members (B) are arranged each with their narrow sides butting adjacent to each other with a selectable distance between two shuttering elements and the gaps between the insulating bodies (W, W’) of the structural members (B) and the shuttering elements are completely filled with concrete. :

® 71

94. Method according to claim 93, characterised in that the concrete shells are cast in several operations, wherein between the individual operations the concrete must not harden fully.

95. Method according to either of claims 93 or 94, characterised in that to form a vertical prefabricated wall several structural members (B) are arranged in each case butting adjacent to each other in vertical and horizontal directions and in that the lower structural members (B) are each anchored stationarily in a floor slab, wherein adjacent structural members (B) in the horizontal direction are arranged in alignment in a straight line and/or along a curved line and/or at any angle to each other.