Abstract:
A console for joining a façade to a building wall ( 100 ), including a metal wall part ( 1 ) for mounting on the building wall, a metal façade part ( 2 ) for joining to the façade, and a bridge part ( 3 ) that joins the façade part ( 2 ) to the wall part ( 1 ), whereby the bridge part ( 3 ) includes a plastic material and it forms a heat barrier between the wall part ( 1 ) and the façade part ( 2 ) is provided. The bridge part is an injection-molded part made of fiber-reinforced plastic, and in that the bridge part ( 3 ) is injection-molded around the wall part ( 1 ) and the façade part ( 2 ) so as to encapsulate them in certain areas.

Description:
[0001]    The invention relates to a console for joining a façade to a building wall. Such a console is fitted with a metal wall part for mounting on the building wall, a metal façade part for joining to the façade, and a bridge part that joins the façade part to the wall part, whereby the bridge part comprises a plastic material and it forms a heat barrier between the wall part and the façade part. 
       BACKGROUND 
       [0002]    A console of the generic type is disclosed in European patent application EP 2180115 A1. Such a console is provided with a bridge part that forms a heat barrier and thus counters undesired heat dissipation away from the wall via the console. Another console with a heat barrier is disclosed in German utility model DE 202004008376 U. 
       SUMMARY OF THE INVENTION 
       [0003]    It is an object of the present invention to provide a console that is particularly cost-effective to produce and that is very reliable to install and use while, at the same time, having particularly good mechanical and thermal properties. 
         [0004]    The present invention provides a console characterized in that the bridge part is an injection-molded part made of fiber-reinforced plastic, and in that the bridge part is injection-molded around the wall part and the façade part so as to encapsulate them, at least in certain areas, preferably only in certain areas. 
         [0005]    A first basic idea of the invention can be seen in the fact that the bridge part encapsulates the wall part and of the façade part by means of injection-molding. In other words, the bridge part is joined to the wall part and to the façade part in that the latter are encapsulated by means of injection-molding, that is to say, during the production process, the material of the bridge part in the molten state is brought into contact with the wall part and the façade part, and the bridge part hardens as it comes into contact with the wall part and the façade part. Since, according to the invention, the bridge part is in the form of an injection-molded encapsulation, an especially good mechanical bond can be achieved in the console that is also particularly reliable in terms of the forces and the temperature fluctuations in the façade area. 
         [0006]    According to the invention, the bridge part constitutes a heat barrier, in other words, a thermal insulator. In particular, the material of the bridge part has a lower thermal conductivity than the material of the wall part and of the façade part. The bridge part joins the façade part to the wall part, and the façade part is mechanically affixed to the wall part by means of the bridge part. Preferably, the façade part, especially when the façade has been dismantled, is joined to the wall part exclusively via the bridge part. In this manner, parallel heat flows can be prevented and an even better thermal insulation can be achieved. The façade part and/or the wall part are preferably joined directly to the bridge part, which can further simplify the production. 
         [0007]    Moreover, the invention provides for the bridge part to be made of a fiber-reinforced plastic. As will be explained in detail below, such a plastic often displays thermal and mechanical properties that render it particularly well-suited for use in a console. 
         [0008]    The façade preferably can be a rear-ventilated cladding for external walls, especially one according to standard DIN  18516 - 1 , that is to say, the console is advantageously employed where a façade of a closed external wall is pre-installed. In particular, the invention can be used in combination with a layer of insulation material through which the console passes, whereby the bridge part is advantageously embedded into the insulation material layer. The façade suitably has a plurality of panels. The façade panels are preferably joined to the consoles according to the invention, particularly to their façade parts, by means of a support profile structure which especially can be made of metal. If a support profile structure is present, according to the invention, it can be seen as a constituent of the façade. Advantageously, the façade part of the console according to the invention has means to hold a support profile, for instance, a clamp. 
         [0009]    It is especially preferable for the bridge part to have two support flanges which are at a distance from each other and which join the façade part and the wall part. In this manner, the forces that occur, especially wind forces, can be withstood very efficiently. Advantageously, the two support flanges of the bridge part, preferably exclusively the two support flanges, are injection-molded around of the wall part and of the façade part so as to encapsulate them in certain areas. This translates into a very compact design. The two support flanges preferably run parallel to each other and/or horizontally. 
         [0010]    It is likewise advantageous for the bridge part to have four bars arranged in a cross, especially in a diagonal cross, by means of which the two support flanges are joined together. The intersection area of the four bars, in other words, the area where the four bars meet, is preferably situated between the two support flanges, especially in the center between the two support flanges. In particular, the gate mark of the bridge part configured as an injection-molded part can be at the intersection area of the bars. These bars can very easily and reliably stiffen the two support flanges so that especially the force of the weight of the façade can be supported very reliably. Moreover, this can give rise to a particularly advantageous combination of the cross shape of the bars and the use of fiber-reinforced plastic in an injection-molding process. After all, the design of the bridge part as a diagonal cross, that is to say, in the form of an X, can bring about a specific orientation of the fibers. In particular, the fibers can be oriented in such a way that the preferential direction of the fibers in the bars is parallel to the individual bars. In this manner, the fibers are oriented primarily diagonally and particularly in the direction of the main flux of force when under load due to wind forces and/or the force of the weight. 
         [0011]    According to the invention, the four bars can encompass four fields, namely, especially two crosswise fields that open towards the support flanges, and two opposing lengthwise fields that open towards the wall part or the façade part. The crosswise fields suitably have a smaller opening angle than the lengthwise fields. 
         [0012]    It is especially preferred for the material thickness of the bridge part in at least one of the lengthwise fields, preferably in both lengthwise fields, at least in certain areas, preferably everywhere, to be less than on the bars. As an alternative or in addition, it is advantageous for the material thickness of the bridge part in at least one of the crosswise fields, preferably in both crosswise fields, at least in certain areas, preferably everywhere, to be less than on the bars. These embodiments take into account the fact that the forces that occur can essentially already be absorbed by the connection flanges and the bars, so that the fields located between the bars can be configured so as to be relatively weak, without this entailing any major mechanical losses. Since the material in the fields can thus be relatively thin, the thermal insulating property of the bridge part can be further improved, without this entailing any major mechanical losses. According to the invention, the term “material thickness” refers to the thickness in a direction running perpendicular to the fields and/or perpendicular to the cross shape of the bars. In a properly mounted console, this direction can preferably be the horizontal direction. The four bars preferably have a constant material thickness and/or they all have the same material thickness gradient. 
         [0013]    In particular, the material thickness in at least one of the lengthwise fields, preferably in both lengthwise fields, can be equal to zero, at least in certain areas. For this reason, it is especially preferred for at least one of the two lengthwise fields to have at least one opening. Advantageously, both lengthwise fields have at least one opening. These openings can form, for example, air cushions that can even further reduce the heat conductivity of the bridge part. The term “opening” refers especially to a cutout that passes through the bridge part perpendicular to the fields and/or perpendicular to the cross shape of the bars. 
         [0014]    It is likewise advantageous for at least one of the crosswise fields to be closed, preferably completely, so that it advantageously does not have an opening. In particular, both crosswise fields can be closed, preferably completely. This can be advantageous with an eye towards the mechanical stability. With this embodiment, in certain cases, it is also possible to prevent or at least reduce the formation of seams in the area of the connection flange. Preferably, a higher percentage of the surface of the crosswise fields is closed than in the case of the lengthwise fields. 
         [0015]    It is also preferred for the wall part to have a plate element with two opposing flat sides and two opposing lengthwise sides, and/or for the façade part to have a plate element which has two opposing flat sides and two opposing lengthwise sides and which runs preferably coplanar to the plate element of the wall part. This can be advantageous in terms of the production work involved. In particular, the wall part and/or the façade part can be configured in the form of an extruded part. The wall part can have, for instance, a mounting plate that is placed on the wall from which the plate element of the wall part protrudes, especially at a right angle. The façade part can have a holding clamp that projects from the plate element of the façade part, whereby a support profile of the support profile structure of the façade can be clamped between the holding clamp and the plate element of the façade part. Preferably, an end face of the façade part faces an end face of the wall part. In a properly mounted console, the bars and the two plates advantageously run in at least one vertical plane, preferably in precisely one vertical plane. 
         [0016]    In particular, it can be provided that the opposing lengthwise sides of the wall part and/or the opposing lengthwise sides of the façade part are enclosed in some areas by the bridge part, whereby the bridge part preferably creates a snug fit for the opposing lengthwise sides of the wall part or for the opposing lengthwise sides of the façade part. Thanks to this snug fit on the lengthwise side, the force of the weight of the façade can be transferred very effectively. 
         [0017]    According to the invention, the fiber-reinforced plastic has a matrix and a plurality of fibers. The matrix can especially be a thermoplastic, for instance, a polyamide, preferably polyamide 6.6. 
         [0018]    Another preferred configuration of the invention lies in the fact that the coefficient of thermal expansion of the matrix is greater, and the coefficient of thermal expansion of the fibers is smaller, than the coefficient of thermal expansion of the two plate elements. This can again yield an advantageous interaction with the geometry according to the invention since, due to the fact that the preferential direction of the fibers in the bars advantageously runs parallel to each individual bar, the coefficient of thermal expansion of the bars as seen along the bars is between the coefficient of thermal expansion of the fibers and the coefficient of thermal expansion of the plastic matrix. Therefore, in this preferred configuration, the thermal expansion of the bridge part can be adapted to the thermal expansion of the adjacent metal wall part and/or to that of the adjacent metal façade part, so that an undesired thermal stress at the transition from the bridge part to the wall part or else at the transition from the bridge part to the façade part can be avoided. Owing to the fiber orientation along the diagonals, the thermal expansion of the plastic can bed made to approximate the thermal expansion of the adjacent metal. 
         [0019]    Advantageously, it can be provided that the four bars, preferably the four bars and the two support flanges, especially preferably the entire bridge part, are mirror symmetrical to one plane of symmetry, preferably to two planes of symmetry. A plane of symmetry can especially be perpendicular to the cross shape of the bars and can run through the wall part and the façade part. In a properly mounted console, this plane of symmetry is preferably in the horizontal. A symmetrical design can be advantageous in terms of the mechanical properties and/or the fiber orientation. In particular, the symmetrical configuration can make it possible to install the console in several orientations at identical load values, which also simplifies the use. 
         [0020]    Another advantageous refinement of the invention is that the gate mark of the bridge part is in at least one plane of symmetry of the bridge part. As a result, the fiber orientation and/or the mechanical properties can be further improved. 
         [0021]    It is particularly preferred for the bridge part to have precisely one gate mark, which simplifies the production. 
         [0022]    Preferably, it can be provided that a gate mark of the bridge part is situated in an intersection area of the four bars, in other words, especially in the center of the diagonals. Owing to the geometry according to the invention and to the selection of a gate mark in a plane of symmetry and/or in the intersection area of the bars, the fibers in the bridge part can be systematically oriented, as a result of which the following is attained:
       a) The thermal expansion of the plastic molded part approximates the thermal expansion of the metal parts that are touching each other. This minimizes mechanical stresses in the component when temperatures fluctuate.   b) The main flux of force runs in the fiber direction, thus utilizing the greater material strength in the fiber direction.       
 
         [0025]    Preferably, the wall part and/or the façade part has/have a ribbed structure that is encapsulated by the bridge part by means of injection-molding. This permits a better transfer of force between the individual parts. In particular, the ribbed structure can be provided on the plate element of the wall part or of the façade part. Each ribbed structure suitably has a plurality of ribs that run on at least one flat side, preferably on both flat sides, of the appertaining plate element and/or parallel to the end face of the appertaining plate element. 
         [0026]    It is likewise preferred for the bridge part to be configured as a single piece. This reduces the production work and improves the mechanical stability even further. In particular, the bars and the connection flanges can be configured as a single piece. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The invention will be explained in greater detail on the basis of preferred embodiments that are schematically depicted in the accompanying figures, whereby individual features of the embodiments presented below can be implemented in conjunction with the invention either individually or else in any desired combination. The figures show the following schematically: 
           [0028]      FIG. 1 : a first embodiment of a console according to the invention, in a perspective view; 
           [0029]      FIG. 2 : a detailed view of the console according to  FIG. 1 , from the side; and 
           [0030]      FIG. 3 : a second embodiment of a console according to the invention, in a perspective view. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Identically functioning elements are designated by the same reference numerals in the figures. 
         [0032]    A first embodiment of a console according to the invention is shown in  FIGS. 1 and 2 . The console has a wall part  1  that is mounted on a building wall  100 , a façade part  2  that is mounted on a façade, as well as a bridge part  3  that mechanically holds the façade part  2  on the wall part  1 , thereby creating a heat barrier between the wall part  1  and the façade part  2 . 
         [0033]    The wall part  1  has a mounting plate  19  that lies flat on the building wall  100 , and a plate element  11  which projects from the mounting plate  19  at a right angle and on which the bridge part  3  is arranged. The façade part  2  likewise has a plate element  21 . The plate element  21  of the façade part  2  is supported by the bridge part  3 . In this context, the plate element  21  of the façade part  2  runs parallel—and coplanar in the embodiment shown—to the plate element  11  of the wall part  1 . 
         [0034]    The plate element  11  of the wall part  1  has two opposing flat sides  12  and  13 , two opposing narrow lengthwise sides  14  and  15  as well as a narrow, free end face  16 . The plate element  21  of the façade part  2  likewise has two opposing flat sides  22  and  23 , two opposing narrow lengthwise sides  24  and  25  as well as a narrow, free end face  26 . The free end face  26  of the façade part  2  and the free end face  16  of the wall part  1  face each other as well as the bridge part  3 . 
         [0035]    When the flat sides  12 ,  13 ,  22  and  23  and/or the end faces  16  and  26  have been properly installed, as a rule, they run vertically, that is to say, the lengthwise sides  14  and  24  are above the lengthwise sides  15  and  25 , respectively. Fundamentally, however, installation in which the flat sides  12 ,  13 ,  22  and  23  run horizontally or obliquely is also possible. 
         [0036]    The bridge part  3  is an injection-molded part made of fiber-reinforced plastic. It has a first, preferably upper, support flange  31 , and a second, preferably lower, support flange  32 . The two support flanges  31 ,  32  run at a distance from each other, preferably in the horizontal direction, each from the wall part  1  to the façade part  2 , and they join the façade part  2  to the wall part  1 . In this context, the two support flanges  31  and  32  of the bridge part  3  are injection-molded around the wall part  1  and the façade part  2  so as to encapsulate them. Each one of the two support flanges  31  and  32  is in contact with the two flat sides  12  and  13  of the wall part  1  and with the two flat sides  22  and  23  of the façade part  2 . Preferably, the first support flange  31  can also be in contact with the lengthwise side  14  of the wall part  1  and the lengthwise side  24  of the façade part  2 , and/or the second support flange  32  can be in contact with the lengthwise side  15  of the wall part  1  and with the lengthwise side  25  of the façade part  2 . 
         [0037]    The bridge part  3  also has four bars  35 ,  36 ,  37 ,  38  which are joined together by means of the two support flanges  31 ,  32  and which stiffen the two support flanges  31  and  32  with respect to each other. The four bars  35 ,  36 ,  37 ,  38  form a cross shape and run in a parallel, especially coplanar, plane to the plate elements  11  and/or  21 , whereby the intersection area of the four bars  35 ,  36 ,  37 ,  38 , in other words, the area where the four bars  35 ,  36 ,  37 ,  38  meet, is situated in the center between the two support flanges  31  and  32 . The four bars  35 ,  36 ,  37 ,  38  and the two support flanges  31  and  32  are configured so as to be mirror-symmetrical to a plane that is perpendicular to the cross shape of the four bars  35 ,  36 ,  37 ,  38  and that runs between the two support flanges  31  and  32  (in  FIG. 2 , this plane of symmetry is perpendicular to the drawing plane and runs from left to right). The four bars  35 ,  36 ,  37 ,  38  and the two support flanges  31  and  32  are also configured so as to be mirror-symmetrical to another plane of symmetry which is perpendicular to the cross shape of the four bars  35 ,  36 ,  37 ,  38  and which intersects the two support flanges  31  and  32  (in  FIG. 2 , this second plane of symmetry is perpendicular to the drawing plane and runs from top to bottom). 
         [0038]    The gate mark  40  of the bridge part, in other words, the area where the fiber-reinforced plastic material was fed into the mold during the injection-molding process, is located in the intersection area of the four bars  35 ,  36 ,  37 ,  38 . In the four bars  35 ,  36 ,  37 ,  38 , the preferential direction of the fibers of the fiber-reinforced plastic material is approximately parallel to the appertaining bar, as indicated by arrows in  FIG. 2 . 
         [0039]    In the plane of their cross shape, the four bars  35 ,  36 ,  37 ,  38  enclose four fields  41 ,  42 ,  43 ,  44 , namely, two diametrically opposing crosswise fields  41  and  42  that, starting from the intersection area of the bars  35 ,  36 ,  37 ,  38 , open towards the support flange  31  or the support flange  32 , and two diametrically opposing lengthwise fields  43  and  44  that, starting from the intersection area of the bars  35 ,  36 ,  37 ,  38 , open towards the wall part  1  or the façade part  2 . The crosswise fields  41  and  42  have a smaller opening angle than the lengthwise fields  43  and  44 . 
         [0040]    In the embodiment shown, the fields  41 ,  42 ,  43 ,  44  are not filled with plastic material and they each form an opening. However, the fields  41 ,  42 ,  43  and/or  44  can also be filled with plastic material. The following then preferably applies to the material thicknesses: 0≦a≦b≦c, wherein
   a stands for the material thickness in the individual lengthwise field(s)  43  and/or  44 ,   b stands for the material thickness in the individual crosswise field(s)  41  and/or  42 , and   c stands for the material thickness in at least one of the bars  35 ,  36 ,  37 ,  38 , preferably in all of the bars.   
 
         [0044]    This relationship is not limited to the embodiment shown in  FIGS. 1 and 2 , but rather, can also be employed for other geometries according to the invention. 
         [0045]    The console shown in  FIGS. 1 and 2  especially can withstand the force F 1 , for example, the wind force on the façade and the force F 2 , for instance, the force of the weight of the façade. 
         [0046]    Another embodiment of the console according to the invention is shown in  FIG. 3 . The embodiment of  FIG. 3  implements a number of features of the embodiment from  FIGS. 1 and 2  in an analogous manner, so that the above-mentioned description can be employed analogously and only the differences will be elaborated upon below. 
         [0047]    The support flanges  31  and  32  in the embodiment of  FIG. 3  are structured. They have struts and depressions located between the struts. 
         [0048]    The crosswise fields  41  and  42  in the embodiment of  FIG. 3  are completely filled. In the lengthwise fields  43  and  44 , there are struts  53  and  54  that adjoin the intersection area of the bars  35 ,  36 ,  37 ,  38  and whose material is thinner than that of the bars  35 ,  36 ,  37 ,  38 . Moreover, the lengthwise fields  43  and  44  have openings  45  and  46 . The strut  53  is located between the opening  45  and the intersection area, while the strut  54  is located between the opening  46  and the intersection area. The surface area of the strut  53  is smaller than the adjacent opening  45 , and the surface area of the strut  54  is smaller than the adjacent opening  46 . 
         [0049]    In the embodiment of  FIG. 3 , the plate elements  11  and  12  of the wall part  1  and the façade part  2 , respectively, have a ribbed structure  18  and  28 , on which the bridge part  3  is joined to the wall part  1  or to the façade part  2 . The mounting plate  19  of the wall part  1  has a hole through which an anchor bolt can be inserted in order to anchor the mounting plate  19  to the building wall. The façade part  2  of  FIG. 3  has a holding clamp  70  that is arranged on the plate element  21  of the façade part  2 . During the installation procedure, a support profile  101 —only shown in rough schematic form in sections—of the support profile structure of the façade can be held temporarily by clamping between the holding clamp  70  and the plate element  21 . In the plate element  21  of the façade part  2 , there are openings that allow the temporarily clamped support profile  101  to be permanently screwed to the façade part  2 .