CN102691372B - Composite pre-formed construction articles - Google Patents

Composite pre-formed construction articles Download PDF

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Publication number
CN102691372B
CN102691372B CN201210183786.6A CN201210183786A CN102691372B CN 102691372 B CN102691372 B CN 102691372B CN 201210183786 A CN201210183786 A CN 201210183786A CN 102691372 B CN102691372 B CN 102691372B
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CN
China
Prior art keywords
embedded
wall
cases
concrete
expanded polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CN201210183786.6A
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Chinese (zh)
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CN102691372A (en
Inventor
J·鲍曼
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Syntheon Inc
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Syntheon Inc
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Publication of CN102691372A publication Critical patent/CN102691372A/en
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Expired - Fee Related legal-status Critical Current
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/026—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of plastic
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/17—Floor structures partly formed in situ
    • E04B5/18—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly cast between filling members
    • E04B5/19—Floor structures partly formed in situ with stiffening ribs or other beam-like formations wholly cast between filling members the filling members acting as self-supporting permanent forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/48—Special adaptations of floors for incorporating ducts, e.g. for heating or ventilating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8611—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf
    • E04B2/8617—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf with spacers being embedded in both form leaves
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E04B2001/2439—Adjustable connections, e.g. using elongated slots or threaded adjustment elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403—Connection details of the elongated load-supporting parts
    • E04B2001/2448—Connections between open section profiles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2466—Details of the elongated load-supporting parts
    • E04B2001/2469—Profile with an array of connection holes
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2481—Details of wall panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2484—Details of floor panels or slabs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/867—Corner details

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Foundations (AREA)
  • Floor Finish (AREA)

Abstract

The invention discloses a composite building panel that includes a central body, substantially parallelepipedic in shape, containing an expanded polymer matrix, having opposite faces, a top surface, and a bottom surface; at least one embedded framing stud longitudinally extending across the central body between the opposite faces, having a first end embedded in the expanded polymer matrix, a second end extending away from the bottom surface of the central body, and one or more expansion holes in the embedded studs between the first end of the embedded stud and bottom surface through which the polymer matrix expands. A concrete layer can optionally cover a portion of the top surface and/or bottom surface. The building panel can be positioned perpendicular to a structural wall and/or foundation to provide a floor panel. The second end of the framing studs can be embedded in a second central body to provide an insulated concrete form.

Description

The pre-formed construction articles of compound
This divisional application is based on Chinese invention patent application 200680006096.6(international application no PCT/US2006/006686), denomination of invention " pre-formed construction articles of compound ", the patent application in February 24 2006 applying date divisional application.
Technical field
The present invention relates to preformed building and structural slab, this structural slab comprises one or more reinforcement structure member in the thermoplastic matrix (matrix) being embedded in foaming, also relates to inner locking (blocking) and heat insulation (insulated) concrete blinding supporting (bracing) part.
Background technology
The building component that known use is made up of the foamed plastics of such as foamed polystyrene, this building component is plate or section bar (section) parts of suitable shape and size.These parts provide heat insulation and sound insulation function, and are accepted by building industry for a long time.
It is also known that enough from bearing characteristics in order to make this building component have, one or more stiffening profile bar of suitable shape must be merged in the block (mass) of foamed plastics.
United States Patent (USP) 5787665 and 5822940 discloses the molded combined wall board for construction of buildings, and this wallboard comprises at least one light metal specification (gauge) the hollow wall bone in the regular tetragonal body of foam of polymers and body.Wall bone edge also has the surface of foam of polymers, and therefore dry wall plate (drywall) can be attached to this on the surface.
United States Patent (USP) 6098367 discloses the building system being applied to building, to form wall by the modularization foldable frame can placing prefabricated board (blocks) or plate.The framework with opposing passage, bar, prefabricated board or plate can resist high wind and taphrogeny preferably.
United States Patent (USP) 6167624 discloses a kind of method of the foam for panel for the production of polymer, and the method comprises the following steps: the foamed material providing polymer; The foamed material of cutting polymer, until arrive predetermined cut point; Structure is received from predetermined cuts point cutting pillar subsequently in the foamed material of polymer; And strut member is slided in pillar reception structure, to produce the foam for panel of polymer.
United States Patent (USP) 6235367 discloses a kind of molded building products, and it has one or more wall and kernel section, and comprises: have the composite interstitial substance of resin system, catalyst and the filler compound for the formation of wall; For the formation of the foam core system of kernel section, curing agent and drier.Be provided with structural reinforcement member supporting system, for strengthening the structural integrity of compound.Be provided with locking system, for connecting one or more molded product.
EP 0 459 924 disclose a kind of be made up of plastic foam material certainly support building component, a kind of floor member specifically, it comprises the basic centerbody for parallelepiped, during molding process, in this centerbody, be integrally formed with stiffening profile bar, this stiffening profile bar is made up of the foil being configured as I-beam.
United States Patent (USP) 5333429 discloses a kind of composite plate with structural bearing wooden frames, and the body that this plate is parallelepiped by foamed synthetic basic is formed.Plate has multiple vertical passage, the whole height of these passage extend through plates.A series of uniform intervals and staggered passage open wide on the adjacent surface of plate, and have T-shaped cross section.In the passage that these open wide, be combined with the wooden pillar of T-shaped cross section, trunk (stem) part of this pillar exposes unlimited passage, and stretches out from the surface of plate.
WO 2002/035020 discloses a kind of building component, and this building component comprises the body be made up of plastic foam material and the slab-shaped covering be connected with body.Slab-shaped covering comprises multiple basic connection and the basic adjacent segment for U-shaped, and these adjacent segment are provided with for by the related device of slab-shaped part mechanical ground fastening (clinch) to plastic foam material.
Although above-mentioned building component has light weight on the one hand, easier to install and low cost, the flexibility of their application in the art and use but then is also subject to their poor fire performances so far and/or makes the restriction of conk (grow) tendency on the combination with decorative surfaces be attached thereon.
The fire line of this deficiency is main relevant with the following fact, namely, the building component be made up of foamed plastics shows the ability being not enough to reliably keep outer cover in the inflammable fusing occurred due to the heat from fire or liquid form, and this outer cover is such as outer surface decoration (finish) or the grey mud layer holding foamed polymer body portion.
In fact, when exposed to a fire, foamed plastics is shrunk at once and can flows and the deformed reduction volume block burnt, and causes the separation of outer cover in some cases, and makes rapidly total collapse.
In addition, too early " aging " of the frosting accompanying by these cover layers may cause undesirable separation of outer cover in some cases, this separation can by be exposed to thermal source, dust, smog, steam or near building component source chemical substance and be typically further exacerbated.
United States Patent (USP) 6298622 and WO 2004/101905 disclose a kind of by using the method overcoming the problems referred to above from supporting building component being used as the floor component of building and the foamed plastics of wall.This building component comprises: centerbody, and the shape of this centerbody is parallelepiped substantially, and has two apparent surfaces; At least one stiffening profile bar, this profile strip extends transversely across centerbody between the surface of centerbody, and is embedded in foamed plastics; For supporting the lath of the suitable cladding material of at least one deck, this lath is connected to the fin (fin) of stiffening profile bar, and this fin flushes with at least one in the surface of building component, and substantially parallel with this surface.But the moisture accumulated between lath and building component can cause fungi and fungus growth, and electric wire is easily made to extend and the ability of portion's cutting building component has limited the desirability of the method.
Concrete wall in Architectural Construction normally produces in the following manner, that is, the template wall that first setting two is parallel, then by the space between filling concrete to template.After concrete is hardening, builder removes template, leaves the concrete wall hardened.
The prior art has shortcoming.The formation of concrete wall owing to erectting template, wait for concrete hardening and take off time that template needs but poor efficiency.Therefore the prior art is expensive labour-intensive process.
Therefore, develop the technology for the formation of modular concrete wall, these technology use foam heat insulating material.Modularization shaping wall is erect in parallel to each other, and when filling concrete to described between the walls time, two shaping walls are relative to each other held in place by attaching parts.But shaping wall still remains on original position after the concrete is cured.That is, after the concrete is cured, the shaping wall be made up of foam heat-insulating measurement is a permanent part for building.The concrete wall made by this technology can stacking many floors be so high on top of each other, to form all walls of building.Except by retaining except efficiency that shaping wall obtains as the part of permanent structure, shaping wall is often for building provides enough heat insulation.
Although the modification that prior art comprises many propositions is improved, for each design still existing defects to obtain by this technology.In the prior art for keeping the attaching parts of wall to be constructed by (1) plastic foam, (2) high-density plastic or (3) metal bridge, these attaching parts are non-structural support members, that is, once concrete hardening, then attaching parts are by inoperative.However, these parts also provide heat insulation and sound insulation function, and are accepted by building industry for a long time.
Thus, current isolation concrete forming technology needs to use little molded foam prefabricated board, this foam prefabricated board normally 12 to 24 inches high, and has the full-length of four feet.Need to support, with a large amount of levels and vertical joint of correctly locating prefabricated board during pouring concrete, their use is restricted to shorter length of walls and lower wall height.The wall penetrator of such as window and door needs prepared dexterously and design shaping, to stand the pressure be applied to during pouring concrete above them.Plaster Grace Person to be difficult to dry wall plate to hang on such a system due to positioning module built in the problem of lathing (furring strips) wherein.Metal in current design or the lathing of plastics are discontinuous in essence, and are usually embedded in foam surface.The feature existed in current prefabricated board formation system needs skilled labour, the layout time of length, the locking of design and support and unconventional decoration skill.This causes the wall being costly unsuitable for larger wall Application in Building.When compared with traditional concrete construction technology, the work with high degree of skill needed for placement in block sytem, locking, support and application ornament seriously limits the use of this system.
Solve straight in larger layout and accurately a kind of method of the problem of the wall of (true) designs larger prefabricated board.This increase is restricted to 24 inches high and 8 feet long by existing manufacturing technology.Other system produces the opposed foam plastic plate of hot line cutting, and described plate uses metal or plastic connector mechanically to link together in the second operation.These plates normally 48 inches wide and 8 feet high, and do not comprise continuous print lathing.
But, in said method, neither one is enough to solve following problem, that is, form ejection due to the concrete applied pressure by perfusion at higher wall At The Height, build quickly and easily with unskilled labour, and with the attachment point that can easily determine easily decorative wall.
Thus prior art needs overcome the preformed building panel of the compound of the problems referred to above and be formed with the heat insulating concrete of inner locking and support component.
Summary of the invention
The invention provides a kind of composite building board, this composite building board comprises:
Centerbody, the shape of described centerbody is parallelepiped substantially, and described centerbody is made up of expanded polymer matrix, and has relative two sides, top surface and relative basal surface;
At least one embedded framing stud, described embedded framing stud cross center's body between described relative two sides longitudinally extends, and there is the first end be embedded in expanded polymer matrix, extend with the second end of the basal surface away from centerbody and one or more inflation port, described inflation port is arranged in wall embeded bone between the first end and the basal surface of centerbody of interior wall embeded bone, wherein, centerbody comprises the polymer substrate expanding through inflation port; And
Concrete layer, described concrete layer covering top surface and/or basal surface are at least partially.
The present invention also provides a kind of composite floor panels, and this composite floor panels comprises:
Centerbody, the shape of described centerbody is parallelepiped substantially, and described centerbody is made up of expanded polymer matrix, and has relative two sides, top surface and relative basal surface;
One or more embedded floor joists, described embedded floor joists cross center's body between described relative two sides longitudinally extends, and there is first end, the second end and one or more inflation port, described first end is embedded in expanded polymer matrix, and there is the first cross member extended from first end, described first cross member contacts top surface or side's extension on the top generally, described the second end extends with the basal surface away from centerbody, and there is the second cross member extended from the second end, described inflation port is arranged in wall embeded bone between the first end and the basal surface of centerbody of interior wall embeded bone,
Wherein centerbody comprises the polymer substrate expanding through inflation port;
The space wherein limited by the basal surface of centerbody and the second end of embedded joist is suitable for holding utility lines; And
Wherein composite floor panels is positioned to usually perpendicular to structural wall and/or basis.
The present invention also provides a kind of insulated concrete form, and this insulated concrete form comprises:
First body, the shape of described first body is parallelepiped substantially, and described first body is made up of expanded polymer matrix, and has relative two sides, first surface and relative second surface;
Second body, the shape of described second body is parallelepiped substantially, and described second body is made up of expanded polymer matrix, and has relative two sides, first surface and relative second surface; And
Wall embeded bone in one or more, described interior wall embeded bone between the first surface of every body portion, cross the first body and the second body longitudinally extends, and first end during there is the expanded polymer matrix being embedded in the first body, being embedded in the second end in the expanded polymer matrix of the second body and one or more inflation port, described inflation port is arranged in the part that wall embeded bone is embedded in the first body and the second body;
Wherein, the first body and the second body comprise the polymer substrate expanding through inflation port; And the space limited between the first surface and the first surface of the second body of the first body can receive the concrete be cast in wherein.
The present invention provides a kind of insulated concrete form system in addition, this insulated concrete form comprises multiple above-mentioned insulated concrete form, and at least one wherein in the outward flange of each insulated concrete form or inward flange forms the joint with another insulated concrete form.
The invention still further relates to a kind of building, it comprises one or more above-mentioned heat insualting building plate, floor panel, insulated concrete form and insulated concrete form system.
The present invention relates to a kind of method of construction of buildings in addition, and the method comprises:
Above-mentioned composite building board is assembled on generally flat surface, and
Raise the first end of composite building board, the second end keeps static simultaneously, and result is directed to building panel, to form the wall of building.
The invention still further relates to a kind of building built according to said method.
Accompanying drawing explanation
Fig. 1 illustrates the cross-sectional view according to preformed building panel of the present invention;
Fig. 2 illustrates the side view according to preformed building panel of the present invention;
Fig. 3 illustrates the perspective view according to construction process of the present invention;
Fig. 4 illustrates the fragmentary perspective view according to horizontal rail of the present invention;
Fig. 5 illustrates the rearview according to wall system of the present invention;
Fig. 6 illustrates the front perspective view according to wall system of the present invention;
Fig. 7 illustrates the rear flank perspective view according to wall system of the present invention;
Fig. 8 illustrates the decomposition diagram of a part for the wall system of Fig. 7;
Fig. 9 illustrates the perspective view according to wall system of the present invention;
Figure 10 illustrates the partial top perspective view be attached to according to the moulded parts on preformed building panel of the present invention;
Figure 11 illustrates the cross-sectional view of the moulded parts in Figure 10;
Figure 12 illustrates the cross-sectional view according to preformed building panel of the present invention;
Figure 13 illustrates the perspective view according to floor system of the present invention; And
Figure 14 illustrates the perspective view according to floor system of the present invention;
Figure 15 illustrates the cross-sectional view according to preformed building panel of the present invention;
Figure 16 illustrates the cross-sectional view according to preformed building panel of the present invention;
Figure 17 illustrates the cross-sectional view according to concrete compound preformed flooring system of the present invention;
Figure 18 illustrates the cross-sectional view according to preformed building panel of the present invention;
Figure 19 illustrates the perspective view of the metallic walls bone used in the present invention;
Figure 20 illustrates the cross-sectional view according to concrete compound preformed flooring system of the present invention;
Figure 21 illustrates the cross-sectional view according to concrete compound preformed flooring system of the present invention;
Figure 22 illustrates the cross-sectional view according to preformed building panel of the present invention;
Figure 23 illustrates the perspective view of the metallic walls bone used in the present invention;
Figure 24 illustrates the cross-sectional view according to concrete compound preformed flooring system of the present invention;
Figure 25 illustrates the cross-sectional view according to concrete compound preformed flooring system of the present invention;
Figure 26,27 and 28 illustrates the cross-sectional view of the metallic walls bone that can use in preformed building panel according to the present invention;
Figure 29 illustrates the fragmentary elevational view according to preformed building panel of the present invention;
Figure 30 illustrates the top view of the template of the cast concrete according to preformed isolation of the present invention;
Figure 31 illustrates the top view of the template of the cast concrete according to preformed isolation of the present invention;
Figure 32 illustrates the cross-sectional view of the template of the cast concrete according to preformed isolation of the present invention;
Figure 33 illustrates the fragmentary perspective view of the embedded wall bone used in the present invention;
Figure 34 illustrates out the perspective view of the template of the cast concrete according to preformed isolation of the present invention;
Figure 35 illustrates the concrete of the template of the cast concrete according to isolation of the present invention and the perspective view of embedded wall bone parts;
Figure 36 illustrates the concrete of the template of the cast concrete according to isolation of the present invention and the perspective view of embedded wall bone parts;
Figure 37 illustrates the fragmentary perspective view of the metallic walls bone used in the present invention;
Figure 38 illustrates the plane of the template system of the cast concrete according to isolation of the present invention;
Figure 39 illustrates the template corner unit of the cast concrete according to isolation of the present invention; And
Figure 40 illustrates the manufacturer/Customer of design customization according to composite building board of the present invention.
Detailed description of the invention
Below for illustrative purposes, term " on ", D score, " interior ", " outward ", " right side ", " left side ", " vertically " and their derivative should be directed as in the accompanying drawings about the present invention.However, it should be understood that the present invention can adopt substitute variants and sequence of steps, unless illustrated on the contrary.Should also be understood that particular device that is shown in the drawings and that illustrate in the following description and process are exemplary embodiments of the present invention.Therefore, the specific dimensions about the embodiment disclosed herein should not be considered to limit the present invention with other physical features.To in the explanation of embodiments of the invention, at this with reference to the accompanying drawings, wherein identical Reference numeral indicates same characteristic features of the present invention.
Outside pointing out unless otherwise, all numerals or the statement of the instruction quantity used in the specification and in the claims, distance or tolerance all should be understood to all be modified by term " approximately " in all instances.Therefore, unless the contrary indicated otherwise, the digital parameters proposed in following description and appended claims can wish the characteristic that obtains and the approximation that changes according to the present invention.At all be not intended to the application of the principle of the equivalent limiting the defeated scope of claim, at least also should understand each digital parameters by the common technology of rounding off of application according to the quantity of the significant digits of report.
Although the digital scope and the parameter that propose broad range of the present invention are approximations, the numerical value proposed in concrete example is as far as possible accurately reported.But any numerical value comprises the inevitable certain error caused by the standard deviation found in their respective measuring methods all inherently.
And, should be understood that any digital scope quoted at this is all intended to comprise the subrange be included in wherein.Such as, the scope of " 1 to 10 " to be intended to be included between described minimum of a value 1 and described maximum 10 and to comprise all subranges of described minimum of a value 1 and described maximum 10; That is, there is the minimum of a value being equal to or greater than 1 and the maximum being equal to or less than 10.Because disclosed digital scope is continuous print, so they comprise each value between minimum of a value and maximum.Unless pointed out in addition especially, the various digital scopes of specifying in this application are approximations.
As used in this; term " expandable polymer substrate " refers to the polymeric material of particle or pellet form; this polymeric material is perfused with blowing agent; be placed in a mold with convenient particle and/or bead and heat is applied in thereon time; the vaporization (as described below) of blowing agent realizes the turgid cell shape structure in the formation of cellular texture and/or particle and/or bead; and the outer surface of particle and/or bead is fused together, to form the continuous blocks of the polymeric material conformed to the shape of mould.
As used herein, term " polymer " " implication be include but not limited to homopolymers, copolymer and graft copolymer.
As used herein, the implication of term " (methyl) acrylic acid " and " (methyl) acrylate " is the derivative comprising acrylic acid and methacrylic acid, and such as term " (methyl) acrylate " is intended to the Arrcostab being often called as the correspondence of acrylate and (methyl) acrylate comprised.
The invention provides preformed building panel, this preformed building panel comprises one or more partly exposed reinforcement structure member longitudinally extended or bar, and the remainder strengthening structure member is partly encapsulated in the polymer substrate as the expansion of thermal break.Strengthen structure member and can form longitudinal flange on any side, to be provided for the attachment point of exterior object to plate.The perforation be encapsulated in the reinforcement structure member in the polymer substrate of expansion allows vertically to melt.The perforation strengthened in the exposed part of structure member is provided for the attachment point of the installation of cross-brace and public utility (utility).Tongue and groove tie point are designed to plate and are abutted against and provide osculum and the attachment point for exterior object.The region that the parts that the sunk area of relative plate end provides " C " passage extended with bottom with the top along structure member are connected to parts.By longitudinal hole alterable in diameter and position of the polymer substrate of expansion, and the region being provided for the placement of public utility while alleviating structure and the passage of discharging for gas.Plate manufacture is by using the semicontinuous or continuous print molding process allowing variable plate length to realize.
The embedded framing stud used in the present invention or base plate joist can have any suitable material to make.Suitable material be for preformed building panel gain in strength, those materials of stability and structural integrity.This material provides the embedded framing stud of the requirement meeting applicable method of testing known in the art, as non-limiting example ASTM A 36/A 36M-5, the ASTM A 1011/A 1011M-05a of various types of steel, ASTM A 1008/A 1008M-05b and ASTM A 1003/A 1003M-05.
Suitable material includes but not limited to class of construction plastics, composite, pottery, their combination and analog.Suitable metal includes but not limited to alloy and the combination of aluminium, steel, stainless steel, tungsten, molybdenum, iron and these metals.In a particular embodiment of the present invention, metallic rod, wall bone, joist and/or parts are made up of light gauge metal.
Suitable class of construction plastics include but not limited to reinforced thermoplastic, thermosetting resin and reinforced thermosetting resin.Thermoplastic comprises by can repeatedly by thermoplastic and the polymer that the material of underhardening is again made when cooling and foam of polymers.Suitable thermoplastic polymer includes but not limited to cinnamic homopolymers and copolymer, C 2to C 20the homopolymers of alkene and copolymer, C4 to C20 diene, polyester, polyamide, C2 to C20(methyl) homopolymers of acrylate and copolymer, PEI, Merlon, polyphenylene oxide, polyvinyl chloride, polyurethane and their combination.
Suitable thermosetting resin is such resin, that is, when being heated to their solidification point, even at elevated temperatures, also can bear the shape that the chemical crosslink reaction causing them to solidify also keeps them rigidly.Suitable thermosetting resin includes but not limited to alkyd resins, epoxy resin, diallyl phthalate resin, melamine resin, phenolic resins, mylar, polyurethane resin and urea, and these thermosetting resins can pass through cross-linking reaction by as the glycol of non-limiting example, trihydroxylic alcohol, polyalcohol and/or formaldehyde.
Structure and their combination that reinforcement material in thermoplasticity and/or thermosetting resin and/or filler include but not limited to the structure of carbon fiber, aramid fibre, glass fibre, metallic fiber, fabric fibre or above-mentioned fiber, glass fibre, carbon black, graphite, clay, calcium carbonate, titanium dioxide, fabric fibre or above-mentioned fiber can be included in.
The non-limiting example of class of construction plastics is the thermosetting polyester or vinyl ester resin system strengthened with glass fibre, described glass fibre meets the requirement of required method of testing known in the art, and the non-limiting example of described method of testing is ASTM D790, ASTM D695, ASTM D3039 and ASTM D638.
Thermoplasticity and thermosetting resin can comprise other additive alternatively, as non-limiting example ultraviolet (UV) stabilizing agent, heat stabilizer, fire retardant, structural strengthening agent, pesticide and their combination.
The thickness of embedded framing stud or embedded base plate joist (strengthening embedded bar) is at least 0.4mm, at least 0.5mm in some cases, being at least 0.75mm in other cases, is at least 1mm in some cases, is at least 1.25mm in other cases, and be at least 1.5mm in some cases, and its thickness can reach 10mm, reach 8mm in some cases, reach 6mm in other cases, reach 4mm in some cases, and reach 2mm in other cases.The thickness of embedded framing stud or embedded base plate joist will depend on the purposes of preformed building panel.
In an embodiment of the present invention, embedded bracing piece, wall bone, joist and/or parts have hole or opening along their length, and to promote the fusing of the plastic material expanded, and any heat bridge reduced in bracing piece, wall bone, joist and/or parts connects effect.
Expanded polymer matrix forms the expanded polymer body hereinafter illustrated.Expanded polymer matrix is typically from expandable molded thermoplastic.These expandable thermoplastics are made up of any suitable thermoplastic homopolymer or copolymer.Be particularly suited for the homopolymers being derived from vinyl aromatic monomer used, described vinyl aromatic monomer comprises styrene, isopropyl styrene, alpha methyl styrene, core methyl styrene, chlorostyrene, 2-methyl-2-phenylpropane ethene, and analog, and by the copolymer that other monomer one or more of is prepared by the combined polymerization of the above-mentioned vinyl aromatic monomer of at least one, the non-limiting example of described other monomer one or more of is divinylbenzene, (non-limiting example is butadiene to the diene of conjugation, isoprene, 1, 3-and 2, 4-hexadiene), alkyl methacrylate, alkyl acrylate, acrylonitrile and maleic anhydride, wherein vinyl aromatic monomer percentage by weight is in the copolymer at least 50%.In an embodiment of the present invention, styrene polymer, specifically polystyrene is used.But, also can use other suitable polymer, such as polyolefin (such as polyethylene, polypropylene), Merlon, polyphenylene oxide and their mixture.
In a particular embodiment of the present invention, expandable thermoplastic is expandable polystyrene (EPS) plastics.These plastics can be convenient to expand and the bead of moulding process, particulate or other particle form.The particle be polymerized in water slurry process is spherical substantially, and useful for molded expanded polymer body hereinafter described.These particles can be screened, thus make their size from about 0.008 inch (0.2mm) to about 0.1 inch (2.5mm) change.
Any conventional method can be used to make expandable thermoplastic be perfused with suitable blowing agent.As non-limiting example, pour into and realize by blowing agent being added to water slurry between the polymerization period of polymer, or by suspended polymer particles again in an aqueous medium, then as U.S. Patent No. 2, the instruction of 983,692 is mixed into blowing agent and realizes.The material producing gas when any gas material or heating all can be used as blowing agent.Traditional blowing agent comprises the aliphatic hydrocarbon comprising 4 to 6 carbon atoms in the molecule, such as butane, pentane, hexane and such as CFC with the halogenated hydrocarbons of HCFC, described aliphatic hydrocarbon seethes with excitement at the temperature of the softening point lower than selected polymer.Also the mixture of these aliphatic hydrocarbons blowing agents can be used.
Or, water can be mixed with these aliphatic hydrocarbons blowing agents, or can as United States Patent (USP) 6, water is used as unique blowing agent by the instruction of 127,439,6,160,027 and 6,242,540, in these patents, uses water retention agent.Percentage by weight as the water of blowing agent can change from 1-20%.United States Patent (USP) 6,127, the original text of 439,6,160,027 and 6,242,540 is by reference to being contained in this.
The usual preexpanding of the thermoplastic be poured is at least 0.5lb/ft 3(0.008g/cc) density, in some cases at least 1lb/ft 3(0.016g/cc), at least 1.25lb/ft in other cases 3(0.02g/cc), at least 1.5lb/ft in some cases 3(0.024g/cc), at least 2lb/ft in other cases 3(0.032g/cc), and in some cases at least about 3lb/ft 3(0.048g/cc).And the density of the plastics of the preexpanding be poured can up to 35lb/ft 3(0.56g/cc), in some cases up to 30lb/ft 3(0.48g/cc), and in other cases up to 25lb/ft 3(0.4g/cc).The density of the preexpanding plastics be poured can be the arbitrary value in above-mentioned value or change between the arbitrary value in above-mentioned value.Pre-dilation step is undertaken, described traditional heating medium such as steam, hot-air, hot water or radiant heat by the bead be poured via any traditional heating dielectric heating traditionally.In U.S. Patent No. 3,023, teach a kind of generally accepted method of the preexpanding for realizing the thermoplastic be poured in 175.
The thermoplastic be poured can be as in U.S. Patent Application Serial Number 10/021, and the foam cells shaped polymer plastics of instruction in 716, the instruction of this patent application is by reference to being contained in this.Foam cells shape plastics can be polystyrene, this polystyrene preexpanding also comprises volatile foaming agent, based on the weight of polymer, the percentage by weight of this blowing agent is in the level being less than 6.0, percentage by weight change in some cases from the percentage by weight of about 2.0 to about 5.0, and the percentage by weight change in other cases from the percentage by weight of about 2.5 to about 3.5.
Can be included according to the vinyl aromatic monomer of the polyolefinic interpretation in expandable thermoplastic resin of the present invention and in-situ polymerization at United States Patent (USP) 4,303,756 and 4,303,757 and U.S. Application Publication 2004/0152795 in open, the relevant portion of described patent and Shen Qing Publication is by reference to being contained in this.The non-limiting example of the interpretation that can use in the present invention comprises the trade mark can bought from the NOVA chemical company of Pennsylvania, America Pittsburgh and is called be called with the trade mark can bought from Tokyo Sekisui plastics Co., Ltd those.
The polymer substrate expanded can comprise common composition and additive, such as pigment, dyestuff, colouring agent, plasticizer, releasing agent, stabilizing agent, UV absorbers, mould inhibitor, antioxidant etc.Typical pigment includes but not limited to inorganic pigment and organic pigment, described inorganic pigment is carbon black, graphite, expandable graphite, zinc oxide, titanium dioxide and iron oxide such as, red and the purple and copper phthalocyanine blue of described organic pigment such as quinacridone (quinacridone) and green.
In a particular embodiment of the present invention, pigment is carbon black, and the non-limiting example of this material is the EPS that can buy from NOVA chemical company
In another specific embodiment of the present invention, pigment is graphite, and the non-limiting example of this material can have been bought from the BASF Aktiengesellschaft company of the Ludwigshafen of Rhine, Germany
When comprising the material of such as carbon black and/or graphite in polymer plastic, provide the insulative properties of improvement, this insulative properties passes through higher R value (determining as the used ASTM-C578) illustration for the material comprising carbon black or graphite.Thus, the R value that the expanded polymer particles comprising carbon black and/or graphite or the R value of material be made up of this polymer beads are observed than the particle never comprising carbon black and/or graphite or the article be made up of this particle is at least high by 5%.
The particle of preexpanding or " pre-puff (pre-puff) " are heated, to be formed according to preformed building panel of the present invention in hereinafter described semi-continuous or continuous print molding process in the mould closed.
The expanded polymer body used in the present invention comprises and to be molded in expanded polymer body and along the hole that the length of expanded polymer body extends, pipeline or undercut (chase).In an embodiment of the present invention, hole, pipeline or undercut are used for providing path for public utility, and described public utility is such as through the electric wire of wall, ceiling, base plate and ceiling constructed according to the invention, pipeline and exhaust apparatus.
In another embodiment of the present invention, wall unit, floor unit and expanded polymer plate or centerbody have sun " tongue " edge and cloudy " groove " edge, and this " tongue and groove " being convenient to two wall unit matched, floor unit and expanded polymer plate connects.It can be non-directional that tongue and groove connect, and can provide osculum and/or comparatively big uncork to hold pipeline.Typically, tongue and groove are connected in connection place provides plane to allow easily to apply band, with sealed attachment place or joint.
Embodiments of the invention provide wall unit and wall system.As shown in Figure 1, wall unit 10 comprises expanded polymer body 12(centerbody), the embedded metal wall bone 14 towards a left side and the embedded metal wall bone 16(towards the right side strengthen embedded bar).Expanded polymer body 12 comprises the opening 18 of all or part of length of crossing expanded polymer body 12.Embedded metallic walls bone 14 and 16 has the embedded end 20 and 22 of the outer surface 24 not contacting expanded polymer body 12 respectively.Embedded metallic walls bone 14 and 16 also has the exposed end 26 and 28 extended from the inner surface 30 of expanded polymer body 12 respectively.
Expanded polymer body 12 can have as the thickness 5 being at least 2cm from inner surface 30 to the range measurement of outer surface 24, this thickness is at least 2.5cm in some cases, and be at least 3cm in other cases, and can 10cm be reached from the inner surface 30 of expanded polymer body 12, reach 8cm in some cases, and reach 6cm in other cases.Embedded end 26 and 28 can extend any distance above-mentioned distance from inner surface 30, or can change between any distance in above-mentioned distance.
Exposed end 26 and 28 extends with the inner surface 30 at least 1cm away from expanded polymer body 12, in some cases at least 2cm, and at least 3cm in other cases.And exposed end 26 and 28 is extensible reaches 60cm with the inner surface 30 away from expanded polymer body 12, reach 40cm in some cases, and reach 20cm in other cases.In many cases, exposed end 26 and 28 extends a distance from polymer body 12, and this distance is enough to allow public utility to extend along described inner surface 30.Exposed end 26 and 28 can extend any distance described distance from inner surface 30, or can change between any distance in above-mentioned distance.
Embedded end 20 and 22 extends with away from least 1cm in inner surface 30 to expanded polymer body 12, in some cases at least 2cm, and at least 3cm in other cases.And embedded end 20 and 22 is extensible reaches 8cm in some cases to reach 10cm away from inner surface 30 to expanded polymer body 12, and reaches 6cm in other cases.In many cases, embedded end 20 and 22 extends to a distance in expanded polymer body 12, to make embedded end 20 not contact outer surface 24 with 22.The degree of depth limited between outer surface 24 and embedded end 20 and 22 limits a thermal break.Embedded end 26 and 28 can from inner surface 30 to polymer body 12 extend any distance in above-mentioned distance, or can to change between any distance in above-mentioned distance.
In another embodiment of the present invention, embedded end 20 and 22 may extend into the thickness of expanded polymer body 12 in expanded polymer body 12 from 1/10 to 9/10, in some cases from 1/3 to 2/3, and in other cases from 1/4 to 3/4.
In an embodiment of the present invention, embedded metallic walls bone 14 and 16 has shape of cross section, and this shape of cross section comprises embedded length 34 and 36, embedded end 20 and 22 and exposed end 26 and 28.The direction of the orientation reference open end 38 and 40 of embedded metallic walls bone 14 and 16.In an embodiment of the present invention, open end 28 and 40 is mutually remotely directed.In this embodiment, wall unit 10 has comparatively large rigidity, and is easier to carrying and does not bend.
Interval between each embedded metallic walls bone 14 and 16 is typically suitable for meeting local and builds rule (codes) or method, but can be modified with applicable particular demands.Thus, interval the metallic walls bone that mid point from the mid point of exposed end 26 to exposed end 28 is measured can be at least 10cm, at least 25cm in some cases, and be at least 30cm in some cases, and can 110cm be reached, reach 100cm in some cases, reach 75cm in other cases, and reach 60cm in some cases.Interval between embedded metallic walls bone 14 and 16 can be any distance in above-mentioned distance, or changes between any distance in above-mentioned distance.
Opening 18 can have various shape of cross section, and the non-limiting example of this shape of cross section is circular, avette, oval, square, rectangle, triangle, hexagon or octagon.The cross sectional dimensions of opening 18 can be identical, or they can change independently of each other about relative to the size of inner surface 30 and outer surface 24 and position.Interval each opening 18 measured from the mid point of an opening 18 to adjacent apertures 18 can be at least 5cm, at least 10cm in some cases, and can 110cm be reached, in some cases nearly 100cm, reach 75cm in other cases, and reach 60cm in some cases.Interval between opening 18 can be any distance in above-mentioned distance independently or change between any distance in above-mentioned distance.
The cross-sectional area of opening 18 also can change independently of each other, or they can be identical.Because opening 18 will be engaged in the size of expanded polymer body 12, therefore the cross-sectional area of opening 18 is subject to the restriction of the size of expanded polymer body 12.The cross-sectional area of opening 18 can be at least 1cm independently 2, at least 5cm in some cases 2, at least 9cm in other cases 2, and can 130cm be reached 2, reach 100cm in some cases 2, reach 75cm in other cases 2.The cross-sectional area of opening 18 can be the arbitrary value in above-mentioned value independently or change between the arbitrary value in above-mentioned value.
As shown in Figure 1, expanded polymer body 12 can extend a distance with the embedded metal wall bone 14 and 16 replaced be placed on wherein.The length of wall unit 10 can be allow safety carrying and make the minimum random length of the damage of wall unit 10.The length of the wall unit 10 limited as the distance of the end 21 from receiving end 27 to sun can at least 1m typically, at least 1.5m in some cases, at least 2m in other cases, and can 25m be reached, reach 20m in some cases, reach 15m in other cases, reach 10m in some cases, and reach 5m in other cases.The length of wall unit 10 can be the arbitrary value in above-mentioned value, or can change between the arbitrary value in above-mentioned value.In certain embodiments of the present invention, each end of wall unit 10 stops there is embedded metallic walls bone.
The height of wall unit 10 can be allow safety carry and make the minimum arbitrary height of the damage of wall unit 10.The height of wall unit 10 is determined by the length of embedded metallic walls bone 14 and 16.The height of wall unit 10 can be at least 1m, in some cases at least 1.5m, and can reach 3m, in some cases nearly 2.5m.In some cases, in order to increase the stability of wall unit 10, reinforcement cross portion (not shown) can be attached on embedded metallic walls bone 14 and 16.The height of wall unit 10 can be the arbitrary value in above-mentioned value, or can change between the arbitrary value in above-mentioned value.
As shown in Figure 1, expanded polymer body 12 has limited length 72, and there is end 21 and the receiving end 27 of sun, described end 21 comprises forward edge 23 and trailing edge 25, and described receiving end 27 comprises the depression section 29 and extension 31 that are suitable for receiving forward edge 23 and trailing edge 25.Typically, the length of wall unit 10 is by being inserted into the forward edge 23 from the first wall unit 10 in the depression section 29 of the second wall unit 10 and being coupled to each other.Like this, can assemble and/or arrange the larger wall section of the wall unit comprising any amount.
A part for the whole wall system 21 of wall unit 10 typically shown in Fig. 3-11.The bottom of embedded metallic walls bone 14 and 16 is landed in and is attached in base track 44 and top slide rail 42.This structure causes the formation of foot passage 52 and top passageway 54.Passage 52 and 54 can be filled with the expansile polymeric material of correspondingly-shaped, or can be filled with moulded parts to be engaged in passage 52 or 54.
As non-limiting example, moulded parts 58 can insert in top passageway 54, and as shown in FIG. 10 and 11, is attached in top slide rail 42 by being inserted by securing member 60 in the hole 62 in top slide rail 62.Moulded parts 58 provides thermal break for exposed metal track.
Passage due to plate end exposes embedded metallic walls bone 14 and 16 on both sides, and therefore road 52 and 54 provides favorable characteristics of the present invention.When having installed top slide rail 42 and base track 44, this feature has overcome basic structure problem of the prior art by the active mechanical connection being provided to the both sides of embedded metallic walls bone.
With reference to Fig. 3,5 and 7-9, embedded metallic walls bone 14 and 16 can have the public utility hole 46 of the length separation along them.Public utility hole 46 is for holding public utility, and described public utility is such as wiring and the water pipeline (particularly as shown in Figure 9) of electricity, phone, cable television, loudspeaker and other electronic equipment.Public utility hole 46 can have various shape of cross section, and non-limiting example is circular, avette, oval, square, rectangle, triangle, hexagon or octagon.The cross-sectional area in public utility hole 46 also can change independently of each other, or they can be identical.Because public utility hole 46 will be engaged in the size of embedded metallic walls bone 14 and 16, and reduce their structural integrity and intensity indistinctively, therefore the cross-sectional area in public utility hole 46 is subject to the restriction of the size of embedded metallic walls bone 14 and 16.The cross-sectional area in public utility hole 46 can be at least 1cm independently 2, at least 2cm in some cases 2, at least 5cm in other cases 2, and can 30cm be reached 2, reach 25cm in some cases 2, reach 20cm in other cases 2.The cross-sectional area of opening 18 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
In an embodiment of the present invention, public utility hole 46 can have ledge surface that is flanged and that roll in many cases, provides additional strength to give embedded metallic walls bone.Flanged hole allows to use the material of lighter specification to obtain identical architectural characteristic.
Fig. 5-8 illustrates a wall system 21, and wherein three wall unit are connected.When the end of two wall unit run into form turning, external corners attachment element 47 by the end winding support of two wall unit to together.And, extra metallic walls bone 49 can be comprised to increase the intensity at the turning formed.Thus the wall system end embedded metal wall bone 51 that comprises interconnective bottom slide rail 44 and top slide rail 42 and be fixed together at the attaching unit place, turning extended along the height of each wall unit.
The opening of window and door is provided for by the end with two or more embedded metal wall bones (as shown at 53) placed adjacent one another formation opening.Upper-part 55 and lower component 57 are connected to embedded metallic walls bone to form the opening of tape frame.This opening is suitable for easily receiving the window and door that manufacture in advance.
Improve intensity and the globality of wall system 21 by comprising wrenching bar 61, described wrenching bar is disposed through the opening in the public utility hole 46 in such as embedded metallic walls bone 14 and 16.Wrenching bar 61 is attached on embedded metallic walls bone 14 and 16, and although wrenching bar 61 can be arranged to any suitable angle forming intensity and the globality that can strengthen wall system 21 with embedded metallic walls bone 14 and 16, but as shown in the figure, wrenching bar 61 is arranged to form substantially vertical relation with metallic walls bone 14 and 16.Wrenching bar in the present invention and metallic walls bone can be comprised comprise the commodity can bought from the Dietrich industrial group of Pennsylvania, America Pittsburgh and be called those, and at United States Patent (USP) 5,784,850 and 6,021, disclosed in 618 those, the relevant portion of described patent is by reference to being contained in this.
Various metallic structural components in wall system 21 can be fixed by weld part 71 and/or screw 73 or be attached to and go up each other.
The concrete advantage of this wall unit and wall system is included in the ability easily laying public utility before combination with decorative surfaces is attached to the uncoated end portion of embedded metallic walls bone.Exposed metallic walls bone is convenient to on-the-spot structural design (framing) change and is increased, and gives local building official, to check design by exposed for the structure division of assembly.
With reference to Fig. 9, in an embodiment of the present invention, wall unit 10 comprises expanded polymer body 12(centerbody) and strengthen embedded bar towards the embedded metal wall bone 16(on the right side), this embedded metal wall bone 16 comprises flange 11 and has inflation port 13 and the embedded end 22 of outer surface 24 not contacting expanded polymer body 12 of the public utility hole 46 of the exposed part being arranged in wall embeded bone 16, the built-in part of wall embeded bone 16.Embedded metal wall bone 16 also has the uncoated end portion 28 extended from the inner surface 30 of expanded polymer body 12 respectively.
The purposes of inflation port 13 is, when molded expanded polymer body 12, polymer substrate expands through inflation port 13 and the polymer expanded fusion.This allows polymer substrate wrap up by the fusion in expanded matrix and keep embedded wall bone 16.In an embodiment of the present invention, inflation port 13 has ledge surface that is flanged and that roll in many cases, provides additional strength to give embedded metal wall bone.
Be provided with the public utility space being suitable for holding public utility limited by inner surface 30 and the flange 11 of expanded polymer body 12.Typically, flange 11 has attaching combination with decorative surfaces thereon (as said), and this ostentatious side limits public utility space further.
In an embodiment of the present invention, public utility space is suitable for and it is dimensioned to reception standard and/or the parts that manufacture in advance, the cabinet of such as window, door, medicine-chest and customization and shelf.
In one embodiment of the invention, public utility hole 46 is suitable for allowing public utility (as shown in the figure, electric wire 15) transversely to extend in direction relative to interior wall embeded bone 16.
Public utility can be one or more that select from following object, namely, water pipeline (drinking water, or as the hot water piping for radiation heating of non-limiting example), waste line (waste lines), undercut, telephone wire, cable television line, computer line, optical cable, satellite dish connection, antenna, electric wire, ventilation shaft (ductwork) and gas-pipe line (gas lines).
In a particular embodiment of the present invention, wall unit 10 is attached in base track 44.In this embodiment, base track 44 is suitable for the volume that maintenance one volume at least equals the expanded foam matrix of liquid state in expanded polymer body 12 or fusing form.In some cases, this volume by the bottom 101 of base track 44 and side 103 and in the space limited by base track 44 in the part of wall embeded bone 16 limit.
Suitable ostentatious non-limiting example comprise timber, rigid plastics, wood parquet, concrete slab, cement plate, dry wall plate, plasterboard, particieboard, hard plastic board, laths of metal, they combination or there is other suitable material any of decoration and/or structure function.
And the air gap between the inner surface of expanded polymer body and combination with decorative surfaces can improve air and circulate, this can minimize or prevent mouldy.In addition, because metallic walls bone does not directly contact with outer surface, so the heat bridge avoided via high conductance embedded metal wall bone connects, and insulative properties is improved.
The present invention also provides the floor unit and floor system that comprise composite floor panels.Floor panel generally includes centerbody and two or more embedded floor joists, described centerbody is parallelepiped shape substantially, hold expanded polymer matrix, and there is relative two sides, top surface and relative basal surface, described embedded floor joists cross center's body between relative two sides longitudinally extends, there is the first end be embedded in expanded polymer matrix, the second end and one or more inflation port, described first end has contact top surface or on the top square the first cross member extended from first end generally, described the second end extends with the basal surface away from centerbody, and there is the second cross member extended from the second end, described inflation port is arranged in embedded floor joists between the first end and the basal surface of centerbody of embedded floor joists.Centerbody holds the polymer substrate expanding through inflation port as mentioned above.Embedded floor joists comprises one or more public utility hole, described public utility hole is arranged in embedded joist between the basal surface and the second end of embedded joist of centerbody, and is suitable for holding utility lines by the space that the basal surface of centerbody and the second end of embedded floor joists limit.Composite floor panels is positioned to usually perpendicular to structural wall and/or basis.
As shown in figure 12, floor unit 90 comprises expandable polymer sheet 92(centerbody) and embedded metal joist 94 and 96(strengthen embedded bar).Expandable polymer sheet 92 comprises all or part of opening 98 of the length of crossing expanded polymer plate 92.Embedded metal joist 94 and 96 has the embedded end 104 and 106 contacted with the top surface 102 of expanded polymer plate 92 respectively.Embedded metal joist 94 and 96 also has the uncoated end portion 108 and 110 extended from the basal surface 100 of expanded polymer plate 92 respectively.
Embedded metal joist 94 and 96 comprises respectively from the first cross member 124 and 126 that embedded end 104 and 106 extends respectively, described first cross member contacts with top surface 102 usually, and uncoated end portion 108 and 110 comprises respectively respectively from the second cross member 128 and 129 that uncoated end portion 108 and 110 extends.The ventilation shaft receiving and be placed between the embedded metal joist 94 and 96 adjacent with basal surface 100 is can be oriented to by the space of the basal surface 100 of expanded polymer plate 92 and the uncoated end portion 108 and 110 of embedded metal joist 94 and 96 and the restriction of the second cross member 128 and 129.
Expanded polymer plate 92 can have as the thickness from top surface 102 to the range measurement of basal surface 100, and the size of this thickness is similar to above about the size described in expanded polymer body 12.
Uncoated end portion 108 and 110 extends with the basal surface 100 at least 1cm away from expanded polymer plate 92, in some cases at least 2cm, and at least 3cm in other cases.And uncoated end portion 108 and 110 is extensible reaches 60cm with the basal surface 100 away from expanded polymer plate 92, reach 40cm in some cases, and reach 20cm in other cases.Uncoated end portion 108 and 110 can extend between any distance above-mentioned distance or any distance in above-mentioned distance from basal surface 100 and extend.
In an embodiment of the present invention, embedded metal joist 94 and 96 has the shape of cross section comprising embedded length 114 and 116, embedded end 104 and 106 and uncoated end portion 108 and 110.The direction of the orientation reference open end 118 and 120 of embedded metal joist 94 and 96.In an embodiment of the present invention, open end 118 and 120 is directed toward each other.In this embodiment, floor unit 90 is suitable for receiving ventilation shaft.As non-limiting example, along the length of embedded metal joist 94 and 96, HVAC pipe can be installed.
As used herein, term " ventilation shaft " refers to any pipe, pipe, passage or other shell, and air flows to reception space by this shell from source; Non-limiting example flow to the air in room from heating and/or air-conditioning equipment, flows, to the fresh air flow of enclosure space and/or from enclosure space to the exhaust-gas flow of the position of enclosure space outside from room to the make-up air of heating and/or air-conditioning equipment.In certain embodiments, ventilation shaft comprises substantially rectangular metal tube, and this metal tube is positioned at below floor and roughly contiguous floor and extends.
Interval between each embedded metal joist 94 and 96 can as described in about the embedded metal wall bone 14 and 16 in wall unit 10.
Opening 98 can have various shape of cross section, and and about the interval similar like that described in the opening 18 in expanded polymer body 12 and cross-sectional area.
As shown in figure 12, expanded polymer plate 92 can extend a distance with the embedded metal joist 94 and 96 replaced be placed on wherein.The length of floor unit 90 can be allow safety carry and make the minimum length of the damage of floor unit 90.The length of floor unit 90 can be as described in the length about wall unit 10.In certain embodiments, the end of floor unit 90 can stop embedded metal joist.
As shown in figure 12, expanded polymer plate 92 has limited length, and there is end 91 and the receiving end 97 of sun, described end 91 comprises forward edge 93 and trailing edge 95, and described receiving end 97 comprises the depression section 99 and extension 101 that are suitable for receiving forward edge 93 and trailing edge 95.Typically, by being interconnected the length of floor unit 90 in the depression section 99 that the forward edge 93 of the first floor unit 90 is inserted into the second floor unit 90.Like this, can assemble and/or arrange the large floor section comprising any quantity floor unit.
The width of floor unit 90 can be allow safety carry and make the minimum any width of the damage of floor unit 90.The width of floor unit 90 is determined by the length of embedded metal joist 94 and 96.The width of floor unit 90 can be at least 1m, in some cases at least 1.5m, and can reach 3m, in some cases nearly 2.5m.In some cases, in order to increase the stability of floor unit 90, reinforcement cross portion (not shown) can be attached on embedded metal joist 94 and 96.The width of floor unit 90 arbitrary value in above-mentioned value, or change between arbitrary value in above-mentioned value.
A part for floor unit 90 whole floor system typically, this floor system comprises multiple composite floor panels described herein, wherein oedoeagus comprises tongue edge and female end comprises groove, described tongue edge and groove are arranged in and the tongue of each panelling and/or groove are in and the corresponding tongue of another panelling and/or fully contacting of groove, to form a plane.The plane set up laterally extends from basis and/or structural wall.
In this floor system, ventilation shaft can be attached on the reinforcement metal bar of at least one composite floor panels.
In addition, flooring material can be attached on one or more first cross member of composite floor panels, or is in contact with it.Any suitable flooring material can be used in the present invention.Suitable flooring material can be attached on cross member and cover the material at least partially of expanded polymer plate.Suitable flooring material includes but not limited to the thin slice of the wood floors section of glued board, solid wood, band tongue and groove, sheet metal, structural plastic, stone, pottery, cement, concrete and their combination.
Usually, floor system forms the plane laterally extended from basis and/or structural wall.
Figure 13 and 14 illustrates floor system 140 and 141 respectively.Floor system 140 is set up by forward edge 93 being contacted to form continuous floor 142 with depression section 99.The same section of single floor panel marks as described above.As mentioned above, the ventilation shaft of various shape type can be fixed in the space limited by the uncoated end portion 108 and 110 of the basal surface 100 of expanded polymer plate 92 and embedded metal joist 94 and 96 and the second cross member 128 and 129.As non-limiting example, rectangular ventilating duct 147 shown in Figure 13, and circular air duct 148 shown in Figure 14.
As illustrated in the embodiment of fig. 13, the wood floors 149 of band tongue and groove are placed in floor unit 90, and are attached on the first cross member 124 and 126.In alternate embodiment (not shown), glued board, plastics, particieboard or other suitable subfloor can be attached on the first cross member 124 and 126, and the wood floors 149 of band tongue and groove are attached on subfloor.
As shown in Figure 3, the end of embedded metal joist 94 and 96 to be landed in joist joist frame (rim) 122 and to be attached on this joist frame, and the second joist frame is attached on another end of embedded metal joist 94 and 96.The flooring base 149 of glued board typically, particieboard or other area supported or flooring material can be attached on the first cross member 124 and/or 126.
With reference to Fig. 3, embedded metal joist 94 and 96 has the public utility hole 127 of opening along their length separation.Public utility hole 127 is for holding the wiring for electricity, phone, cable television, loudspeaker and other electronic equipment.Public utility hole 127 can have various shape of cross section, and non-limiting example is circular, avette, oval, square, rectangle, triangle, hexagon or octagon.The cross-sectional area in public utility hole 127 also can change independently of each other, or they can be identical.Because public utility hole 127 will be engaged in the size of embedded metal joist 94 and 96, and reduce their structural integrity and intensity indistinctively, therefore the cross-sectional area in public utility hole 127 is subject to the restriction of the size of embedded metal joist 94 and 96.The cross-sectional area in public utility hole 127 can be at least 1cm independently 2, at least 2cm in some cases 2, at least 5cm in other cases 2, and can 20cm be reached 2, reach 25cm in some cases 2, reach 20cm in other cases 2.The cross-sectional area in public utility hole 127 can be the arbitrary value in above-mentioned value independently, or can change between the arbitrary value in above-mentioned value.
Inflation port 113 as above is for when molded expanded polymer body 92, and polymer substrate expands through inflation port 113, and the polymer expanded fusion.This allows polymer substrate to wrap up by the fusion in the polymer expanded and keeps interior wall embeded bone 94 and 96.In an embodiment of the present invention, inflation port 113 can have flanged pin and the ledge surface rolled in many cases, provides additional strength to give embedded metal wall bone.
In an embodiment of the present invention, floor system can be placed on basis.But, because of based on be seldom complete level, so a horizontal rail can be attached on basis before arranging floor system.Horizontal rail comprises the top surface with length and two side rails extended from the opposite edges of top surface, and wherein the width of top surface is greater than the width on basis, and the length of top surface and basic same length.Horizontal rail is attached on basis usually in the following manner, that is, be placed on basis when side rails roughly contacts the side on basis by horizontal rail, be positioned to by top surface make it meet level and horizontal rail be for good and all attached on basis.Frame joist can be used to help top surface to be attached on the end of multiple composite floor panels.
More specifically, before floor system is set, horizontal rail 128 can be attached on basis 130 (see Fig. 3 and 4).Horizontal rail 128 can be placed on basis 128 on and be arranged to level.By use via fastener hole 132 securing member 131(shown in be nail, but also can use screw or other suitable device) horizontal rail 128 is fastened to basis 130 on and make level lasting.Also screw 133 can be used horizontal rail 128 to be attached on basis 130 via screw hole 135.Some screw hole 135 can be combined with screw 133, the base flange of joist framework 122 to be attached in horizontal rail 128.Screw 133 also can keep the horizontal level of horizontal rail 128, until obtain more lasting location.Alternatively or in addition, mortar can be applied via mortar hole 134, with the space between fill level track 128 and the top on basis 130.In attaching horizontal rail 128 and/or after arranging mortar fully, floor system can be fastened on basis.
Horizontal rail 128 comprises the side rails 137 being suitable for extending in the part on basis 130.The width of horizontal rail 128 is the lateral separations at the top of the horizontal rail 128 from a side rails 137 to another side rails 137.The width of horizontal rail 128 is typically a bit larger tham the width on basis 130.The width of horizontal rail 128 can be at least 10cm, in some cases at least 15cm, in other cases at least 20cm, and at least 21cm in some cases.And the width of horizontal rail 128 can reach 40cm, reach 35cm in some cases, and reach 30cm in other cases.The width of horizontal rail 128 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
The length of side rails 137 is distances that its top from horizontal rail 128 extends, and is enough to allow horizontal rail 128 is arranged to level and is attached on basis 130 via securing member 131 and fastener hole 132 in length.The length of side rails 137 can be at least 4cm, in some cases at least 5cm, and at least 7cm in other cases.And the length of side rails 137 can reach 20cm, reach 15cm in some cases, and reach 12cm in other cases.The length of side rails 137 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
One embodiment of the present of invention design is suitable for use as the floor of concrete I-beam type or acclivitous thermal insulation board.As shown in figure 15, I-shaped beam slab 140 comprises expanded polymer template 142(centerbody) and embedded metal parts 144 and the embedded bracing piece of 146().Expanded polymer template 142 comprises the opening 148 of all or part of length of crossing expanded polymer template 142.Embedded metal parts 144 and 146 have the embedded end 152 and 156 contacted with the inner surface 150 of expanded polymer template 142 respectively.Embedded metal parts 144 and 146 also have respectively can expanded polymer template 142 outer surface 162 extend uncoated end portion 158 and 160.
Expanded polymer template 142 can have as the thickness from inner surface 150 to the range measurement of outer surface 162, and this thickness is similar to above about described in expanded polymer body 12 dimensionally.
Uncoated end portion 158 and 160 extends with the outer surface 162 at least 1cm away from expanded polymer template 142, in some cases at least 2cm, in other cases at least 3cm.And uncoated end portion 158 and 160 is extensible reaches 60cm with the outer surface 162 away from expanded polymer template 142, nearly 40cm in some cases, in other cases at least 20cm.Uncoated end portion 158 and 160 can extend any distance above-mentioned distance from outer surface 100, or can change between any distance in above-mentioned distance.
In an embodiment of the present invention, embedded metal parts 144 and 146 can have the shape of cross section comprising embedded length 162 and 162, embedded end 152 and 156 and uncoated end portion 158 and 160.The direction of the orientation reference open end 168 and 170 of embedded metal parts 144 and 146.In an embodiment of the present invention, open end 168 and 170 is directed toward each other.In this embodiment, I-shaped beam slab 140 is suitable for being embedded in the concrete that can be applied on outer surface 162.
Interval between each embedded metal parts 144 and 146 can as described in about the embedded metal wall bone 14 and 16 in wall unit 10.
Opening 148 can have various shape of cross section, and and about the interval similar like that described in the opening 18 in expanded polymer body 12 and cross-sectional area.
As shown in figure 15, expanded polymer plate 140 has limited length, and has the positive end 170 that comprises forward edge 172 and trailing edge 174 and comprise depression section 178 and stretch out the receiving end 176 at edge 180, and this depression section is suitable for receiving forward end 172.Typically, by being interconnected the length of I-shaped beam slab 140 in the depression section 178 that the forward edge 172 of the first I-shaped beam slab 140 is inserted into the second I-shaped beam slab.Like this, can assemble and/or arrange the larger ceiling of the I-shaped beam slab that comprises any amount, ceiling, floor or wall section.As from stretching out the width typically at least 20cm of edge 180 to the I-shaped beam slab 140 of the range measurement of trailing edge 174, at least 30cm in some cases, in other cases at least 35cm, and can 150cm be reached, reach 135cm in some cases, reach 125cm in other cases.The width of I-shaped beam slab 140 is the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
I-shaped beam slab 140 comprises I-beam channel 182.When compared with the prior art systems, the advantage of I-shaped beam slab 140 is, the connection between the adjacent panels of prior art is that the light filling bar of the expanded polymer of transferring along I-shaped beam slab 182 is arranged.The thin edges obtained is easy to damage and/or fragmentation during transport and carrying.I-shaped beam slab of the present invention is avoided thin edges section to be exposed to potential damage by being molded in I-beam channel and eliminating this problem,
In an embodiment of the present invention, reinforcing bar or other concrete reinforcing rods can be placed in I-beam channel, so that the concrete I-beam that reinforcing and reinforcement are formed in I-beam channel 182.
In an alternative embodiment of the invention shown in Figure 16, I-shaped beam slab 141 comprises passage 183 and replaces I-beam channel 182.Passage 183 is suitable for receiving circular ventilation ducts or other machinery and public utility parts and equipment, and/or can be filled with concrete as mentioned above.
Figure 17 illustrates the example according to I-beam system 200 of the present invention, wherein passes through to connect four I-shaped beam slabs 140 in the depression section 178 of the second I-shaped beam slab forward edge 172 of the first I-shaped beam slab 140 inserted.Pour into, decorate and arrange concrete to form concrete layer 202, this concrete layer comprises the concrete I-beam 204 be formed in I-beam channel 182.Embodiment shown in Figure 17 is alternate embodiment, wherein the direction of the I-beam channel 182 of each I-shaped beam slab 140 alternately comprises concrete I-beam 204 towards concrete layer 202, or concrete layer 202 and I-beam channel 182 does not comprise concrete dorsad.In an embodiment of the present invention, I-shaped beam slab dorsad can be I-shaped beam slab 141.Or each I-shaped beam slab 140 can comprise concrete I-beam 204 towards concrete layer 202.
In the embodiment shown, uncoated end portion 158 and 160 or to be embedded in concrete layer 202 or exposed.Uncoated end portion 158 and 160 can be used as the attachment point for combination with decorative surfaces 210, and this combination with decorative surfaces comprises timber, rigid plastics, wood based panel, concrete slab, cement plate, dry wall plate, gypsum are pulled, particieboard, hard plastic board or have other suitable material 210 any of decoration and/or structure function or building matrix.Attaching realizes typically via use screw, nail, adhesive or other securing member known in the art.
In an embodiment of the present invention, I-beam system 200 is assembled in the plane, and first end raises, and the second end keeps static simultaneously, and I-beam system 200 is oriented and is approximately perpendicular to plane by result.This is often called as in the art " inclination wall ", and in this embodiment of the invention, I-beam system 200 is called as " inclination wall ".
In another embodiment of the present invention, I-beam system 200 can be used as the floor in structural ceiling or structure.
Embodiments of the invention provide composite building board, and this composite building board comprises: centerbody, and this centerbody is parallelepiped shape substantially, have relative two sides, top surface and relative basal surface; At least one embedded reinforced wall bone, this wall bone cross center's body between relative two sides longitudinally extends, have the first end be embedded in expanded polymer matrix, extend with the second end of the basal surface away from centerbody and one or more inflation port being arranged in wall embeded bone between the first end and the basal surface of centerbody of interior wall embeded bone, wherein centerbody comprises the polymer substrate expanding through inflation port; And concrete layer, this concrete layer covering top surface and/or basal surface are at least partially.
Specific embodiment relates to acclivitous thermal insulation board, and this thermal insulation board is suitable for use as wall or ceiling.As shown in figs. 18-21, one side wallboard 340 comprises reinforced body 341, and this body comprises expanded polymer template 342(centerbody) and embedded metal parts 344 and the embedded bracing piece of 346().Expanded polymer template 342 can comprise the opening 348 of all or part of length of crossing expanded polymer template 342.Embedded metal parts 344 and 346 have the embedded end 352 and 356 do not contacted with the inner surface 350 of expanded polymer template 342 respectively.Embedded metal parts 344 and 346 also have the uncoated end portion 358 and 360 extended from the outer surface 362 of expanded polymer template 342 respectively.
Expanded polymer template 342 can have as the thickness from inner surface 350 to the range measurement of outer surface 362, and this thickness is similar to above about described in expanded polymer body 12 dimensionally.
Uncoated end portion 358 and 360 extends with the outer surface 362 at least 1cm away from expanded polymer template 342, in some cases at least 2cm, and at least 3cm in other cases.And uncoated end portion 358 and 360 is extensible reaches 60cm with the outer surface 362 away from expanded polymer template 342, reach 40cm in some cases, and reach 20cm in other cases.Uncoated end portion 358 and 360 can extend any distance above-mentioned distance from outer surface 362, or changes between any distance in above-mentioned distance.
In an embodiment of the present invention, embedded metal parts 344 and 346 have the shape of cross section comprising embedded length 364 and 366, embedded end 352 and 356 and uncoated end portion 358 and 360.The orientation of embedded metal parts 344 or 46 is with reference to the direction of embedded end 352 and 356.In a particular embodiment of the present invention, embedded end 352 and 356 is mutually away from orientation.In this embodiment, one side wallboard 340 is suitable for making the uncoated end portion 358 and 360 of embedded metal parts 344 or 46 to be embedded in being applied in the concrete 370 of outer surface 362.
Interval between each embedded metal parts 344 and 346 can as described in about the embedded metal wall bone 14 and 16 in wall unit 10.
In an embodiment of the present invention, one side wallboard 340 comprises expanded polymer body 342(centerbody) and embedded metal parts 344 and the embedded bracing piece of 346(), described embedded metal parts comprise flange 311, end, turning 312, be arranged in embedded metal parts 344 with 346 exposed part public utility hole 346, embedded metal parts 344 with 346 the inflation port 313 of built-in part and the embedded end 344 and 346 not contacting inner surface 350.
In an embodiment of the present invention, inner surface 350 can have wrinkled surface 351 that is molded or cutting, and the air that this wrinkled surface strengthens between inner surface 350 and attaching any surface thereon flows.
The use of inflation port 313 is, when molded expanded polymer body 342, polymer substrate expands through inflation port 313, and the polymer expanded fusion.This allows polymer substrate wrap up by the fusion in expanded polymer and keep embedded metal parts 344 and 346.In an embodiment of the present invention, inflation port 313 can have flanged pin and the ledge surface rolled in many cases, provides additional strength to give embedded metal parts.
Opening 348 can have various shape of cross section and and about the interval similar like that described in the opening 18 in expanded polymer body 12 and cross-sectional area.
Reinforced body 341 has limited length, and has the positive end 371 comprising forward edge 372 and the receiving end 374 comprising the depression section 376 being suitable for reception forward edge 372.Typically, by being interconnected the length of one side wallboard 340 in the depression section 378 that the forward edge 372 of the first one side wallboard 340 is inserted into the second one side wallboard.Like this, can assemble and/or arrange larger wall or the ceiling section of the one side wallboard comprising any amount.Width as the one side wallboard 340 from the range measurement of stretching out edge 380 to trailing edge 374 can at least 20cm typically, at least 30cm in some cases, at least 35cm in other cases, and can 150cm be reached, reach 135cm in some cases, and reach 125cm in other cases.The width of one side wallboard 340 can be the arbitrary value in above-mentioned value or change between the arbitrary value in above-mentioned value.
According to the example of one side wallboard 340 of the present invention shown in Figure 20 and 21, wherein use four embedded metal parts 344 and 346.Pour into, decorate and concrete is set to form concrete layer 370, the uncoated end portion 358 and 360 of these concrete layer encases embedded metal parts 344 and 346.
The embedded end 350 and 356 of embedded metal parts 344 and 346 can be used as the attachment point of combination with decorative surfaces 375, described combination with decorative surfaces such as timber, rigid plastics, wood based panel, concrete slab, cement plate, dry wall plate, gypsum are pulled, particieboard, hard plastic board and have other suitable material any and/or the building matrix of decoration and/or structure function, as shown in figs 20 and 21.Attaching realizes typically by using screw, nail, adhesive or other securing member known in the art.
In an embodiment of the present invention, one side wallboard 340 is assembled in the plane, and first end raises, and the second end keeps static simultaneously, and one side wallboard 340 is oriented and is approximately perpendicular to plane by result.This is often called in the art " inclination wall ", and in this embodiment, one side wallboard 340 is called as " be inclined upwardly wall ".
Described be inclined upwardly in the embodiment of wall here, the uncoated end portion of embedded metal parts can be used as bearing (chair), this bearing is used for the correct placement to the center of concrete layer of reinforcement metal silk screen and/or reinforcing bar or other bracing piece, described concrete layer is poured, decorates and arranges, to wrap up uncoated end portion.
Be inclined upwardly in the embodiment of wall in described herein shown in Figure 21, the uncoated end portion 358 and 360 of embedded metal parts 344 and 346 can be used as bearing, this bearing is used for the correct placement to the center of concrete layer 370 of reinforcement metal silk screen 371 and/or reinforcing bar or other bracing piece, described concrete layer is poured, decorates and arranges, to wrap up uncoated end portion.
Another specific embodiment provides known composite building board, wherein the first concrete layer covers top surface at least partially, and at least one first end of wall embeded bone in parcel, and the second concrete layer covers basal surface at least partially, and at least one the second end of the interior wall embeded bone of parcel.
This specific embodiment of the present invention can provide the second thermal insulation board being suitable for use as wall or ceiling.As illustrated in figs. 22-25, two-sided wallboard 440 comprises reinforced body 441, and this body comprises expanded polymer template 442(centerbody) and embedded metal parts 444 and the embedded bracing piece of 446().Expanded polymer template 442 can comprise the opening 448 of all or part of length of crossing expanded polymer template 442.Embedded metal parts 444 and 446 have the first uncoated end portion 452 and the second uncoated end portion 456 extended from the first surface 462 of expanded polymer template 442 respectively.Embedded metal parts 444 and 446 also have the second uncoated end portion 458 and 460 extended from the second face 450 of expanded polymer template 442 respectively.
Expanded polymer template 442 can have as from the second face 450 to the thickness of the range measurement of first surface 462, this thickness dimensionally with above similar like that about described in expanded polymer body 12.
Uncoated end portion is extensible with away from the face 450 of expanded polymer template 442 or face 562 at least 1cm, in some cases at least 2cm, and at least 3cm in other cases.And uncoated end portion is extensible to reach 60cm away from the arbitrary face of expanded polymer template 442, reach 40cm in some cases, and reach 20cm in other cases.Uncoated end portion can extend any distance above-mentioned distance from the arbitrary face of expanded polymer template 442, or extends between any distance in above-mentioned distance.
In an embodiment of the present invention, in uncoated end portion 452,456,458 and 460 the first concrete layer 469 of being embedded in the face of being applied to 450 and 462 and the second concrete layer 470.
Interval between each embedded metal parts 444 and 446 can as described in about the embedded metal wall bone 14 and 16 in wall unit 10.
In an embodiment of the present invention, two-sided wallboard 440 comprises expanded polymer body 442(centerbody) and embedded metal parts 444 and the embedded bracing piece of 446(), described embedded metal parts have end, turning 412, are arranged in the inflation port 413 of the public utility hole 446 of the exposed part of embedded metal parts 444 and 446 and the built-in part at embedded metal parts 444 and 446.
The use of inflation port 413 is, when molded expanded polymer body 442, polymer substrate expands through inflation port 413, and the polymer expanded fusion.This allows polymer substrate wrap up by the fusion in expanded polymer and keep embedded metal parts 444 and 446.In an embodiment of the present invention, inflation port 413 can have ledge surface that is flanged and that roll in many cases, provides additional strength to give embedded metal parts.
Opening 448 can have various shape of cross section and and about the interval similar like that described in the opening 18 in expanded polymer body 12 and cross-sectional area.
Reinforced body 441 has limited length, and has the positive end 471 comprising forward edge 472 and the receiving end 476 comprising the depression section 478 being suitable for reception forward edge 472.Typically, by the forward edge 472 of the first two-sided wallboard 440 is inserted into the length being interconnected two-sided wallboard 440 in the depression section 478 of the second two-sided wallboard.Like this, can assemble and/or arrange the larger wall of the two-sided wallboard that comprises any amount, floor, ceiling or ceiling section.Width as the two-sided wallboard 440 of the range measurement from forward edge 472 to depression section 478 can at least 20cm typically, at least 30cm in some cases, at least 35cm in other cases, and can 150cm be reached, reach 135cm in some cases, and reach 125cm in other cases.The width of two-sided wallboard 440 can be the arbitrary value in above-mentioned value or change between the arbitrary value in above-mentioned value.
Example according to two-sided wallboard 440 of the present invention shown in Figure 24, wherein uses four embedded metal parts 444 and 446.Pour into, decorate and concrete be set to form concrete layer 469 and 470, the uncoated end portion 452,456,458 and 460 of described concrete layer encases embedded metal parts.
Or, as shown in figure 25, one or two in uncoated end portion 452 and 456 and/or 458 and 460 can be used as the attachment point for combination with decorative surfaces 375, and described combination with decorative surfaces such as timber, rigid plastics, wood based panel, concrete slab, cement plate, dry wall plate, gypsum are pulled, particieboard, hard plastic board and have other suitable material any and/or the building matrix of decoration and/or structure function.Attaching realizes typically by using screw, nail, adhesive or other securing member known in the art.The space 476 limited by combination with decorative surfaces 475, uncoated end portion 452 and 456 and expanded polymer body 442 can be used for laying public utility, thermal barrier and the fixture for above-mentioned upholstery.
The invention provides a kind of method constructing building, the method is included in any one of generally flat surface assembling in above-mentioned composite building board, and raising the first end of composite building board, the second end keeps static simultaneously, thus directed building panel is to form the wall of building.
In an embodiment of the present invention, two-sided wallboard 440 is assembled in the plane, and first end raises, and the second end keeps static simultaneously, and two-sided wallboard 440 is oriented and is approximately perpendicular to plane by result.This is often called in the art " inclination wall ", and in this embodiment, two-sided wallboard 440 is called as " be inclined upwardly wall ".
Be inclined upwardly in the embodiment of wall in as shown in figure 25 described herein, the uncoated end portion 458 and 460 of embedded metal parts 444 and 446 can be used as bearing, this bearing is used for the correct placement to the center of concrete layer 470 of reinforcement metal silk screen 471 and/or reinforcing bar or other bracing piece, described concrete layer is poured, decorates and arranges, to wrap up uncoated end portion.
In an embodiment of the present invention, when the uncoated end portion of one side wallboard and two-sided wallboard is wrapped in above-mentioned concrete, public utility hole 346 and 446 is used as such position, namely, in this position, arrange and the warm passing hole of the concrete hardened, and keep thus and be attached on embedded metal parts.In addition, bracing piece to be placed with 446 by public utility hole 346 and is connected embedded metal parts, thus strengthens the wallboard formed further.
As used herein, term " concrete " refers to by will close-burning compound be had to mix to make close-burning mixture set up as known in the art and the hard firmly construction material of the monoblock that bonds with enough water.
In an embodiment of the present invention, concrete can be so-called " lightweight concrete ", wherein has close-burning mixture to comprise the pellet (aggregate) of light weight.The exemplary lightweight concrete composition that can use in the present invention is open in following patent, that is, United States Patent (USP) 3,021,291,3,214,393,3,257,338,3,272,765,5,622,556,5,725,652,5,580,378,6,851,235 and JP 9 071 449, WO 98 02 397, WO 00/61519 and WO01/66485, the relevant portion of above-mentioned patent is by reference to being contained in this.
Wall unit described herein, floor unit, acclivitous thermal insulation board and I-shaped beam slab comprise not as the modification of restriction.Any one in the modification discussed in one embodiment can use ad lib in another embodiment.
Embodiments of the invention shown in Figure 14 illustrate the combination using composite plate described herein, and this combination combines the feature of various plate.This embodiment combines I-shaped beam slab 140 and floor panel 92(be depicted as 92 and 92A).In this embodiment, the receiving end 176 of I-shaped beam slab 140 receives the forward edge 93 of floor panel 92, and the depression section 99 of floor panel 92A receives the forward edge 172 of I-shaped beam slab 140, to provide tongue to be connected with groove, thus set up continuous print floor system 141.In this embodiment, the basal surface 100 of circular ventilation ducts 148 along floor panel 92 between embedded metal joist 94 and 96 is installed.In this embodiment, flooring material is concrete layer 145, and this concrete layer covers floor panel 92 and the top surface 102 of 92A and the outer surface 162 of I-shaped beam slab 140.I-beam channel 182 extends from outer surface 162 and opens wide outer surface 162, and is filled with concrete, and the thickness of concrete layer 145 is enough to the uncoated end portion 158 and 160 of wrapping up I-shaped beam slab 140.Combination in this embodiment provides a kind of heat insulating concrete floor system, and wherein public utility can extend below thermal insulation layer.
In an embodiment of the present invention, lath can be attached to wall unit, floor unit and expanded polymer plate---i.e. building component of the present invention---metallic walls bone, metal joist or metal parts uncoated end portion on.Lath can support the cover layer be made up of suitably construction material.Lath can be included in one or more part that the lateral sides of building component extends with flushing, described building component can to embed in concrete and to be fixed on concrete, for one or more adjacent building component is interconnected and/or is linked together.
Lath can support one or more cover layer, and this lath comprises the laths of metal of the elongation of the diamond-mesh of the length-height rhombus ratio with about 2:1 typically.Diamond length can change between 20mm and 60mm, and rhombus width can change between 10mm and 30mm simultaneously.The laths of metal extended can have the thickness from 0.4mm to 1.5mm, is from 0.4mm to 1.0mm in some cases.
Cover layer can comprise the cover layer of one or more gypsum, plaster, pottery when the fiber selectively with suitable material is strengthened.
In the embodiments of the invention shown in Figure 29, the outer surface 24 of expanded polymer body 12 can have any surface of wishing type.In some cases, outer surface 24 is level and smooth, can cut in outer surface 24 or be molded into groove in other cases, outer surface 24 can have along surperficial spine to promote that air flows in other cases, and in particular situations, as shown in figure 29, outer surface 24 can be suitable for receiving plaster.For the ease of plaster being applied on outer surface 24, can cutting in outer surface 24 or be molded into T-slot 1300.Can use the plaster of any suitable type, non-limiting example comprises natural material plaster or the plaster based on polymer.Thus, by making outer surface 24 comprise T-slot 1300, provide the plate surface being easy to apply plaster.More specifically, T-slot 1300 is provided for the mechanical connection of plaster attachment, and does not need secondary mesh.In a particular embodiment of the present invention, T-slot 1300 allows to use natural material plaster, this is because such plaster can be breathed freely and do not trapped moisture.When not being applied on outer surface 24 by plaster, T-slot 1300 can be used as water condensation passage, or for other decoration technique.
Concrete advantage according to building panel of the present invention, wall unit, floor unit and expanded polymer plate relates to fire line and security.As mentioned above, a part for embedded framing stud or embedded floor joists is exposed, and can comprise (a web of) hole of a web of the length formation along them.By exposed web section with holes in embedded framing stud or embedded floor joists, facilitate air flowing, and in case of fire, the cooling of the web section of embedded framing stud or embedded floor joists occurs.This is extremely important for the out-of-service time extending carrying wall section.Typically, catching fire in test, in central webbing region, the metallic walls bone of having isolated lost efficacy before the wall bone of non-isolated.
As mentioned above, in exposed web section during dowelled spanner bar, embedded framing stud or embedded floor joists are used as radiator, help the central web section heat radiation from embedded framing stud or embedded floor joists, and increase the structural behaviour of wall.
The meltdown property of polymer substrate in the situation of catching fire, by leaving from web fusing more than during 200F when temperature, allows the cooling of the circulation of further air and web, and further promotes the cooling of embedded framing stud or embedded floor joist web section.
As mentioned above, the bottom guide track of wallboard can be designed to be used as drip trays (drip) in a fire and accommodating disc.Bottom guide track zone design becomes to hold the solid of the fusing when polymer substrate burns.Base track is suitable for maintenance one volume, and this volume at least equals the volume of the expanded polymer matrix in the expanded polymer body under liquid or fusing form.Each orbital segment can be designed to have at least 0.2ft 3hold facility, at least 0.25ft in some cases 3, at least 0.3ft in some cases 3, at least 0.4ft in other cases 3, and hold facility can up to 0.75ft 3, in some cases up to 0.65ft 3, and in other cases up to 0.1ft 3liquid state or the material of fusing.Accommodation volume in base track can be the arbitrary value in above-mentioned value or change between the arbitrary value in above-mentioned value.The hold facility of base track is typically designed to accommodation and is contained in typical 48 " × 96 " structure dish in solid.
In such as highly larger comparatively macrotectonics dish, the outside of base track can be slotted, allows the material of fusing to be discharged to the outside of building.This design substantially reduces inner fire spreading during initial fire spreading and rescue work, and improves the security of the internal environment of structure.
Embodiments of the invention provide one heat insulating concrete formation system on the spot, and this system nature is continuous print, the restriction that length is only transported and carried.This heat insulating concrete formation system comprises two relative foam plastic charge levels, and they internally connect and spaced apart by perforation structure metal parts.Foam plastic charge level and metallic spacer aim at suitably vertically and flatly locate concrete by strong steel part in template, allow suitable concrete flowing and decoration workpiece attaching simultaneously.Be molded in structural steel elements wherein and be used as internal support, this support member keeps template straight and aim at during concrete is arranged, eliminates the needs to outermost locking.
And the invention provides preformed insulated concrete form, this concrete blinding comprises one or more reinforcement structure member longitudinally extended or bar, in the expanded polymer body faced by its end is embedded in relatively at least in part.Strengthen the remainder of structure member, the part namely between expanded polymer body is exposed at least in part.The part being wrapped in the end in expanded polymer matrix can provide the thermal break from external environment condition.Strengthen structure member and on any side, flange can be provided with along its length, to be provided for exterior object to the attachment point on plate.The perforation be wrapped in the reinforcement structure member in the end sections in expanded polymer matrix allows expanded polymer particles vertically to melt.The perforation strengthened in the exposed part of structure member is provided for the attachment point of horizontal support piece and/or reinforcing bar, and allows the uniform concrete flowing when concrete is perfused in this insulated concrete form.Tongue and groove or overlapping tie point be designed for plate against, keep the globality of concrete blinding simultaneously.Longitudinal hole can extend through expanded polymer matrix, and can change on diameter and position, to be provided for placing the region of public utility, the passage alleviating and circulate for gas of structure.Plate manufacture is by using semicontinuous or continuous print molding process realization, and this molding process allows variable plate length.
The interior wall embeded bone used in the present invention can be made up of any suitable material as above.In a particular embodiment of the present invention, interior wall embeded bone is made up of light gauge metal.
Interior wall embeded bone can have thickness as above.The thickness of interior wall embeded bone will depend on the purposes of preformed building panel.
In an embodiment of the present invention, interior wall embeded bone has hole along its length or opening, and to promote the fusion of expanded plastics material, and any heat bridge reduced in bracing piece, wall bone, joist and/or parts connects effect.
In the present invention, foam plastic charge level can be molded by any suitable expandable plastic materials as above on molding machine, this molding machine can insert metal parts and form two relative plates, is remained on by composite in continuous or semi-continuous process in their relative position simultaneously.
In a particular embodiment of the present invention, expandable thermoplastic granulates is expandable polystyrene (EPS) particle.These particles can be convenient to as above expansion and the form of the bead of moulding process, particulate or other particle.
More specifically, this insulated concrete form comprises: the first body, and its shape is parallelepiped substantially, and this first body comprises expanded polymer matrix, and has relative two sides, first surface and relative second surface; Second body, its shape is parallelepiped substantially, and this second body comprises expanded polymer matrix, and has relative two sides, first surface and relative second surface; With wall embeded bone in one or more, this interior wall embeded bone crosses the first body and the second body longitudinally extends between the first surface of every body portion, and first end during there is the expanded polymer matrix being embedded in the first body and the second end that is embedded in the expanded polymer matrix of the second body.One or more inflation port is provided with in the part being embedded in wall embeded bone in the first body and the second body.First body and the second body comprise the polymer substrate expanding through inflation port.The space limited between the first surface and the first surface of the second body of the first body can receive the concrete be poured in wherein.
Embodiments of the invention provide insulated concrete form (ICF) and ICF system.As shown in figure 30, ICF 510 comprises the first expanded polymer body 511, second expanded polymer body 512, the embedded metal wall bone 514 towards a left side and the embedded metal wall bone 516(towards the right side and strengthens embedded bar).Embedded metal wall bone 514 and 516 has the embedded end 520 and 522 of the outer surface 524 not contacting the first expanded polymer body 511 respectively.Embedded metal wall bone 514 and 516 has the embedded end 521 and 523 adjacent with the outer surface 525 of the second expanded polymer body 512 respectively.For the height of CIF 510, space 505 is restricted to the space between the inner surface 530 of the first expanded polymer body 511 and the inner surface 531 of the second expanded polymer body 512.
Expanded polymer body 511 and 512 can have the thickness as being clipped to the distance that outer surface 524 or 525 is measured respectively from inner surface 530 or 531 points, this thickness is at least 2cm from the inner surface 30 of expanded polymer body 512, at least 2.5cm in some cases, at least 3cm in other cases, and can 10cm be reached, reach 8cm in some cases, reach 6cm in other cases.The thickness of expanded polymer body 511 and 512 can be the arbitrary dimension in above-mentioned size independently or change between the arbitrary dimension in above-mentioned size.
Embedded end 520 and 522 extends with away from least 1cm in inner surface 530 to expanded polymer body 512, in some cases at least 2cm, in other cases at least 3cm.And embedded end 520 and 522 is extensible reaches 8cm in some cases to reach 10cm away from inner surface 530 to the first expanded polymer body 511, reaches 6cm in other cases.Embedded end 526 and 528 can extend to any distance polymer body 511 in above-mentioned distance from inner surface 530, or changes between any distance in above-mentioned distance.In another embodiment of the present invention, embedded end 520 and 522 may extend into 1/10 to 9/10 of the thickness of the first polymer body 511 in expanded polymer body 511, and in some cases 1/3 to 2/3, in other cases 1/4 to 3/4.
The direction of the orientation reference end 520,521,522 and 523 of embedded metal wall bone 514 and 516.End can be oriented on any direction of intensity, attaching object or the stability being suitable for insulated concrete form.
Interval between each embedded metal wall bone 514 and 516 is typically suitable for meeting local and builds rule and methodology, but can be modified with applicable special requirement.Thus, the interval between metallic walls bone can be at least 10cm, in some cases at least 25cm, at least 30cm in other cases, and can 110cm be reached, in some cases nearly 100cm, reach 75cm in other cases, and reach 60cm in some cases.Interval between embedded metal wall bone 514 and 516 can be any distance in above-mentioned distance, or changes between any distance in above-mentioned distance.
ICF 510 can be placed on situation downward-extension one distance wherein at the embedded metal wall bone 514 and 516 replaced.The length of ICF 510 can be allow safety carry and make the minimum any length of the damage of ICF 510.The length of ICF 510 at least 1m typically, in some cases at least 1.5m, in other cases at least 2m, and can 25m be reached, reach 20m in some cases, reach 15m in other cases, reach 10m in some cases, and reach 5m in other cases.The length of ICF 510 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.In certain embodiments of the present invention, each end of ICF 510 stops there is embedded metal wall bone.
The height of ICF 510 can be allow safety to carry, damage any height that is minimum and that can bear from the concrete pressure be poured in ICF 510.The height of ICF 510 can be at least 1m, in some cases at least 1.25m, and can reach 3m, in some cases nearly 2.5m.In some cases, in order to increase the stability of ICF unit 510, reinforcement cross portion or reinforcing bar (not shown) can be attached on embedded metal wall bone 514 and 516.The height of ICF 510 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
Space 505, namely for the space between the inner surface 530 of the height of ICF 510 and inner surface 531, can be any suitable volume and/or size.Suitable volume and/or size are such sizes, namely, be filled into concrete weight in space 505 little to such an extent as to cause any part of ICF 510 to lose efficacy, namely, concrete is allowed to stave and pass ICF 510, thus concrete volume is not contained in space 505, but described suitable volume and/or size are wanted large and are enough to make perfusion and the concrete arranged can support anything that treat to build on the ICF concrete wall made.Thus, can be at least 5cm with the distance between the inner surface 530 of above-mentioned height and inner surface 531, at least 10cm in some cases, at least 12cm in other cases, and can 180cm be reached, reach 150cm in some cases, and reach 120cm in other cases.In some cases, in order to increase the stability of ICF unit 510, reinforcement cross portion or reinforcing bar (not shown) can be attached on embedded metal wall bone 514 and 516.Distance between inner surface 530 and inner surface 531 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
In a particular embodiment of the present invention, ICF 510 can be used as storm wall (storm wall).In this embodiment, space 505 is filled with concrete described herein, and from inner surface 530 to the distance of inner surface 531 can be at least 2cm, at least 5cm in some cases, at least 10cm in other cases, and can 16cm be reached, reach 14cm in some cases, reach 12cm in other cases.In this storm wall embodiment, the distance between inner surface 530 and inner surface 531 can be the arbitrary value in above-mentioned value, or changes between arbitrary value in above-mentioned value.
Storm wall manufactured according to the present invention can be used as other wallboard described herein any and acclivitous wall.
As shown in figure 30, ICF 510 has limited length, and the first body 511 and the second body 512 have inward flange end 517 and outward flange end 518.Typically, by the inward flange end 517 of an ICF 510 being inserted into adjacent with the outward flange end 518 of another ICF 510 and being interconnected the length of ICF 510, to form continuous print ICF.Thus, can assemble and/or arrange the larger ICF of ICF 510 unit comprising any amount.
Figure 31 illustrates alternate embodiment of the present invention, and wherein except the inner surface 530 of body 511 and the inner surface 531 of body 512 comprise relative internal fixtion section 532 and 534 respectively, ICF 508 is identical with ICF 510.Internal fixtion section 532 and 534 provides the space of the non-rectilinear in ICF 508, to make the concrete be filled in ICF 508 have the section of the larger cross-sectional width of band and to be with the section of smaller cross-sectional area width.
In an alternative embodiment of the invention shown in Figure 32, ICF 509 tool has plenty of uncoated end portion 536 and 538, instead of embedded end 521 and 523.Uncoated end portion 536 and 538 extends with the outer surface 525 at least 1cm away from the second expanded polymer body 512, in some cases at least 2cm, in other cases at least 3cm.Uncoated end portion 536 and 538 can be used for the combination with decorative surfaces of such as above-mentioned dry wall plate, glued board and plate etc. to be attached on ICF 509.And uncoated end portion 536 and 538 is extensible reaches 60cm with the outer surface 525 away from expanded polymer body 512, reach 40cm in some cases, reach 20cm in other cases.Uncoated end portion 536 and 538 can extend any distance above-mentioned distance from outer surface 525, or changes between any distance in above-mentioned distance.
With reference to Figure 32, embedded metal wall bone 514 and 516 can have the public utility hole along their length separation between outer surface 525 and uncoated end portion 536 and 538.Public utility hole (not shown here, but illustrate hereinbefore and illustrate) for holding public utility, such as, for the wiring of electricity, phone, cable television, loudspeaker and other electronic equipment, gas-pipe line and water pipeline.Public utility hole can have various shape of cross section, and non-limiting example is circular, avette, oval, square, rectangle, triangle, hexagon or octagon.The cross-sectional area page in public utility hole can change independently of each other, or they can be identical.Because public utility hole significantly will not reduce their structural integrity and intensity in the size being engaged in embedded metal wall bone, therefore the cross-sectional area in public utility hole is subject to the restriction of embedded metal wall bone 514 and 516.The cross-sectional area in public utility hole can be at least 1cm independently 2, at least 2cm in some cases 2, at least 5cm in other cases 2, and can 30cm be reached 2, reach 25cm in some cases 2, reach 20cm in other cases 2.The cross-sectional area in public utility hole can be the arbitrary value in above-mentioned value independently, or changes between arbitrary value in above-mentioned value.
In an embodiment of the present invention, public utility hole can have ledge surface that is flanged and that roll in many cases, provides additional strength to give embedded metallic walls bone.
Figure 33 and 34 illustrates and relates to ICF 508(Figure 31) the feature of this ICF.The feature of embedded metal wall bone 514 and 516 is, they can comprise inflation port 540 and plug hole 542.Thus, plug hole 544 can be the perforation extended along the vertical axis of embedded metal wall bone 514 and/or 516, and this perforation is positioned to allow flowing freely and fix and position level concrete reinforcement of normal concrete.Similarly, inflation port 540 can be have the perforation of enough diameters or have the slit of enough void area, with the fusion and the flowing that allow polymer substrate to pass through the plastic plate be shaped.
Be molded in light gauge metal structure member wherein, namely embedded metal wall bone 514 and 516, can continuously or semi-continuously be formed, to produce the composite plate of unrestricted length.Structural metal element on strategy externally vertical axis penetrated, to provide inflation port 540, this inflation port allows expandable plastic materials by the flowing of metal parts and fusion.The central vertical axis of metal parts is penetrated to provide plug hole 542, and this plug hole allows flowing freely of normal concrete, and helps fixing and place Horizontal concrete reinforcement material.Figure 35 and 36 illustrates shaping about embedded metal wall bone 514 and 516 and the concrete 550 arranged.
Embedded end 521 and 523 is used as the continuous print lathing of all horizontal rail as described herein, top and polycrystalline substance track, wall penetrator and ceiling and floor tie point, and described lathing extends the direct connection helping ornament materials vertically on centering in advance.
Expandable plastic materials in composite plate is used as forming board when being placed in template by concrete, also provides heat insulation and sound insulation.And the expandable plastic materials face of composite plate is used as forming board when being placed in template by concrete, and also provides heat insulation and sound insulation.
The design of this ICF provides level and vertical concrete path, and this path is produced by two relative plates fixing by light specification framework parts.
When by pouring concrete to the space 505 of this ICF time, in the mullion wall structure that plate designs, form inner concrete post by two relative plates.The concrete core produced in a template is used as the horizontal support member of the light specification framework parts data in this ICF.In the design of mullion wallboard, concrete core allows to strengthen along the level of the axis of the mullion produced between forming board.
In this ICF, the interlock board end formed by inward flange 517 and outward flange 518 is autoregistration, self-packing, and a plate side end is reliably connected to another plate side distal point, forms continuous print level and form placed by the vertical concrete of continuous print.
Figure 37 illustrates one embodiment of the invention, the surface that wherein can be used as the steel part 560 of the embedded metal wall bone 514 and/or 516 in this ICF is formed with pit 565 in opposite direction, produces the concrete concrete adhesive force the surface preventing it from breaking that increase and contact with steel part 560.Pit effect on parts surface adds the shearing resistance of steel and Concrete Composites.When plate is molded as composite construction, the pit on steel surface creates the comparatively strong ties between the steel part on the plastic foam surface of foam and plate.
Figure 38 illustrates the insulated concrete form system 575 for providing basis, and this basis comprises multiple end connects to be formed ICF system 575 ICF 508 to end.Corner unit 552 is for being interconnected parallel ICF line 554 and vertical ICF line 556.Concrete is poured in the space 505 of ICF wall system 575, and is hardened the heat insulating concrete wall system that formed.
As shown in figure 39, corner unit mainly comprises an ICF 508A and the two ICF 508B(directed at angle with an ICF 508A indicates identical part with Reference numeral identical above), wherein round corner section 562 is molded as and comprises an ICF 508A and the 2nd ICF 508B, to form continuous print first body and the second body, and provide the continuous space 505 between them.
The ability of public utility is easily laid before being included in uncoated end portion that combination with decorative surfaces is attached to embedded metal wall bone with reference to the concrete advantage of Figure 32, ICF 509.Exposed metallic walls bone is convenient to the change of on-the-spot structural design and is increased, and gives local building official, to check design by exposed for the structure division of assembly.
The public utility space limited by outer surface 525 and the uncoated end portion 536 and 538 of expanded polymer body 512 can be suitable for holding public utility.Typically, uncoated end portion 536 and 538 has attaching combination with decorative surfaces thereon, and this ostentatious side limits public utility space further.
In an embodiment of the present invention, public utility space is suitable for and it is dimensioned to reception standard and/or the parts that manufacture in advance, the cabinet of such as window, door, customization and shelf.
And the air gap between the outer surface of expanded polymer body 512 and combination with decorative surfaces can improve air and circulate, this can minimize or prevent mouldy.In addition, because metallic walls bone does not directly contact with external environment condition, so the heat bridge avoided via high conductance embedded metal wall bone connects, and insulative properties is improved.
Various embodiment described herein comprises the modification be not intended to as restriction.Any one in the related version discussed in the embodiment of ICF, building, floor, ceiling, wall and/or ceiling floor can use ad lib in the embodiment of ICF, building, floor, ceiling, wall and/or ceiling floor.
In an embodiment of the present invention, lath can be attached in the uncoated end portion of the metallic walls bone of ICF of the present invention, metal joist or metal parts.Lath can support the cover layer be made up of suitable construction material.Lath can be included in one or more part that the lateral sides of building component extends with flushing, described building component can to embed in concrete and to be fixed on concrete, for one or more adjacent building component is interconnected and/or is linked together.
Lath can support one or more cover layer, and this lath comprises the laths of metal of the elongation of the diamond-mesh of the length-height rhombus ratio with about 2:1 typically.Diamond length can change between 20mm and 60mm, and rhombus width can change between 10mm and 30mm simultaneously.The laths of metal extended can have the thickness from 0.4mm to 1.5mm, is from 0.4mm to 1.0mm in some cases.
Cover layer can comprise the cover layer of one or more gypsum, plaster, pottery when the fiber selectively with suitable material is strengthened.
In an embodiment of the present invention, with reference to Fig. 3 and 38, shown concrete blinding system 575 is bases 130, and as mentioned above, wherein horizontal guide rail 128 is attached on this basis.And, the invention provides building, this insulated concrete form system based on this building comprises and one or more floor panel described herein, floor system, wallboard, wall system, acclivitous wall, storm plate, ceiling and/or ceiling floor, described insulated concrete form system has according to attaching of the present invention optional horizontal guide rail thereon.In a particular embodiment of the present invention, this horizontal guide rail can be used alternatively floor panel, floor system, wallboard, wall system, acclivitous wall and/or storm plate to be attached in insulated concrete form system.And for this specific embodiment, this ceiling and/or ceiling floor can be attached in this wallboard, wall system, acclivitous wall and/or storm plate on one or more.Thus novel building is provided.
Can use and manufacture ICF unit of the present invention for molded device that is semi-continuous or continuous print foamed plastic part, this device comprises:
First mould, comprising:
I) diapire, a pair relative sidewall and lid, and
Ii) molded seat, its have and at sidewall, limit the shape that parts in a mold match between diapire and lid;
Second mould, comprising:
I) diapire, a pair relative sidewall and lid, and
Ii) molded seat, its have and at sidewall, limit the shape that parts in a mold match between diapire and lid;
B) for diapire and the lid moved moulds away from diapire and sidewall longitudinally to close and to open the device of mould respectively; And
C) first device, its in an adjustable way away from or described diapire towards mould locate described lid, to control the height of molded seat by the mode of adjustable and basic continous.
This device is configured to comprise above-mentioned reinforcement, embedded metal bar, embedded metal wall bone, embedded metal joist and embedded metal parts.As non-limiting example, at United States Patent (USP) 5,792, method and apparatus disclosed in 481 can be suitable for manufacturing ICF unit of the present invention.United States Patent (USP) 5,792, the relevant portion of 481 is by reference to being contained in this.
Shaping molding technique in batch can be used to manufacture wall unit of the present invention, floor unit and expanded polymer plate.But the method can cause inconsistency, and it is very consuming time and costliness.
In an embodiment of the present invention, can use and manufacture wall unit of the present invention, ceiling units, ceiling unit, floor unit and expanded polymer plate for molded device that is semi-continuous or continuous print foamed plastic part, this device comprises:
A) mould, comprising:
I) diapire, a pair relative sidewall and lid, and
Ii) molded seat, its have and at sidewall, limit the shape that parts in a mold match between diapire and lid;
B) for diapire and the lid moved moulds away from diapire and sidewall longitudinally to close and to open the device of mould respectively; And
C) first device, its in an adjustable way away from or described diapire towards mould locate described lid, to control the height of molded seat by the mode of adjustable and basic continous.
This device is configured to comprise above-mentioned reinforcement, embedded metal bar, embedded metal wall bone, embedded metal joist and embedded metal parts.As non-limiting example, at United States Patent (USP) 5,792, method and apparatus disclosed in 481 can be suitable for manufacturing wall unit of the present invention, floor unit and expanded polymer plate.United States Patent (USP) 5,792, the relevant portion of 481 is by reference to being contained in this.
In an embodiment of the present invention, reinforcement, embedded metal wall bone, embedded metal joist and/or embedded metal parts 220 can be molded into wall unit, floor unit and have in the embedded end 222 of shaping as shown in figure 26 and the expanded polymer plate of straight uncoated end portion 224.Subsequently, straight uncoated end portion can be formed, processes and/or revise to provide the forming end section 228A as shown in the molded component 226A in Figure 27 or the molded component 228B as shown in the molded component 226B in Figure 28.Embedded end 226A and 226B can keep embedded end 222 constant.For bending, processing subsequently, to be shaped or the equipment of amendment and machine are known in the art.
In an embodiment of the present invention, the inner surface of above-mentioned wall unit, floor unit and expanded polymer plate, basal surface or inner face can have the surface of trough of belt, the surface of this trough of belt is molded in and wherein or mechanically applies, and is flowed by the air of the annular space between expansion plastic and any material being attached in the uncoated end portion of the metallic walls bone of above-mentioned wall unit, floor unit and expanded polymer plate, metal joist or metal parts to improve.
The present invention relates to a kind of method of construction of buildings in a first embodiment, and the method comprises:
There is provided basis, this basis has a series of wall with top surface, and this basis can comprise insulated concrete form system of the present invention;
Locate and be fixedly suitable for use as the above-mentioned composite building board of floor unit described herein and/or floor panel or floor system, so that the top surface making floor unit, panelling and/or system span basis wall at least partially;
Any one in above-mentioned wall system is located and is fixed in floor unit or system; And
Above-mentioned canopy system is located and is fixed on the top surface of wall system.
An alternative embodiment of the invention provides a kind of method of construction of buildings, and the method comprises:
There is provided basis, this basis has a series of wall with top surface, and this basis can comprise insulated concrete form system of the present invention;
Locate and be fixedly suitable for use as the above-mentioned composite building board of floor unit described herein and/or floor panel or floor system, so that the top surface making floor unit, panelling and/or system span basis wall at least partially;
Two or more being suitable for use as in the above-mentioned composite building board of wall unit and/or storm plate are located and are fixed to going up at least partially of the top surface of floor unit, on the bottom wherein bottom guide track and top slide rail being attached to composite building board respectively and top; And
The above-mentioned composite building plate being suitable for use as ceiling unit is located and be fixed in the top slide rail of wall unit at least on some.
On the basis of this embodiment, provide a kind of method of building multi-story structure, the method also comprises:
The above-mentioned composite building board being suitable for use as the second floor unit or system is located and is fixed to going up at least partially of the top slide rail of wall unit; And
Two or more being suitable for use as in the above-mentioned composite building board of the second wall unit and/or storm plate are located and are fixed to going up at least partially of the top surface of the second floor unit, on the bottom wherein base track and top slide rail being attached to composite building board respectively and top;
Wherein ceiling unit is fixed in the top slide rail of the second wall unit at least on some.
Thus, the present invention also provides a kind of building, and it comprises one or more above-mentioned floor unit, wall system and canopy system.
Wall unit of the present invention, floor unit and expanded polymer plate provide many advantages.Such as, they typically eliminate the needs to house packing material (wrap).The expanded polymer used in the present invention typically at least has for the equal grade (rating) needed for the local building rule of house packing material.
And, because wall unit of the present invention, floor unit and expanded polymer plate have comprised enough thermal barriers, therefore during building, do not need heat insulation subcontractor.The material page of structure has blocked the low-frequency sound wave caused by external noise effectively.Especially favourable according to the acoustic characteristic of building panel of the present invention, wall unit, floor unit and expanded polymer plate.Typically, the structure of metallic walls bone is with to have serious acoustics or transmission sound problem.Sound can be zoomed into vibration by their ability by metallic walls bone usually.When metallic walls bone is wrapped in the polymer matrix, vibration reduces, and causes acoustics and the sound transmission characteristic of vibration and the hope reduced.
And, due to the prefabricated person's character of this wall unit, floor unit and expanded polymer plate, so need design at the construction field (site) hardly.The time of usually building faster brought owing to using this wall unit, floor unit and expanded polymer plate allows encapsulation comparatively early and guard block, less water stain during causing building.In addition, the hole arranged in wall unit of the present invention, floor unit and expanded polymer plate, opening, pipeline, undercut and space cause connecting up and lay pipeline (plumbing) and less job site waste material faster.
The invention still further relates to a kind of trade (doing business) method, the method allows by the device access building design drawing for molded semicontinuous or continuous print foamed plastic part, to customize size, the shape and size of the various parts of building panel of the present invention, wall unit, floor unit and expanded polymer plate.Building design drawing can be provided via the software on hard disk or via internet connection.For those clients with the Internet capability, access the method is easily, and provides efficient and timesaving method, to design and to manufacture building and/or house unit.
In non-restrictive illustrative embodiment, the architectural design of customer selecting building.This architectural design comprises the specific characteristic of each composite building board treating to use between floors.Architectural design is loaded into processing unit, and this processing unit will design the instruction converted to for device, and this device is used for molded semicontinuous or continuous print foamed plastic part.These commands direct devices are continuously or semi-continuously molded above-mentioned plate and wait to be included in the custom features in each plate.
As non-limiting example, architectural design can comprise: the size of any breach (indentations) in opening required in wall embeded bone in each reinforcement and hole and each composite building board needed for construction of buildings and position; The size of each composite building board, comprise the size and dimension of thickness, width, the following feature of Distance geometry highly, between interior wall embeded bone, namely, each interior wall embeded bone, need to cut to or be formed into any passage in the centerbody of each composite building board, above-mentioned any design feature, for other specific characteristic any of each composite building board and frontispiece (gable) end, described frontispiece end hold the slope of roof or gradient, bay window floor cutting part and other design specific construction characteristic.
Processing unit can be can reading command any computer converted thereof into for the instruction of device or equipment, and described device is used for molded semicontinuous or continuous print foamed plastic part.
Custom features can comprise any above-mentioned architectural design feature.As non-limiting example, custom features can comprise the forming end section straight uncoated end portion be as shown in figure 26 formed as shown in any one in Figure 27 and 28.
In another embodiment of the present invention, interactive computer program can be used for providing above-mentioned architectural design.In an embodiment of the present invention, series of computation machine on-screen menu can be used to input architectural design, wherein select available options on the computer screen.When selecting design button, there is the screen being used for additional option, for revising centerbody, embedded framing stud or embedded floor joists and/or spatial relationship therebetween.Select any menu all to lead another screen, wherein can input above-mentioned concrete architectural design feature and there is the requirement of plate of those features.Upon selection, other customization plate can be inputted.User then can by selecting " order plate " button firm order.Instruction is passed to the device for molded semicontinuous or continuous print foamed plastic part then, and the plate with each architectural design feature of the quantity required is molded and cuts into order specification.In an embodiment of the present invention, all plates are automatically tagged and marking, for being placed on their suitable positions.In another embodiment, customer requirement access guides the interactive program of (step) client by design process substep.Once design, then client can preserve to be designed for and use in the future.Client also may be selected to be order and sends design.
The use of designing program on internet location is of value to manufacturer in every way, and described mode comprises the client circumstances (profiles) that collection can be used for mailing etc. in the future.In addition, the internet location comprising this unique trade method arrives world wide, and be that manufacturer produces fame accreditation, especially when building panel manufacturer be design is uniquely provided and orders the manufacturer of addressable method easily of composite building board.
The advantage provided on his or her individual affair for user of designing program of the present invention is, it is by being allowed for the prompting of his or she client and serving then and there, improves the professional standards of user.Such as, user can take the sketch or design drawing that are used for architectural design to composite building board shop, requires that building panel uses in design drawing or design.In the response, plate business owners, that is, user, can utilize designs program builds a series of composite building board on the computer screen together with the client in his side, and is the benefit of client interpretation customization composite building board.This process provides the first service such as grade for client, eliminates conjecture, and what improve between plate shop and terminal client is mutual, enhances the business fame in this area.
Figure 40 illustrate to carry on trade between composite building board manufacturer 420 and the client 414,416 requiring to manufacture the composite building board customized 400 method.Composite building board is designed program via the hard copy 418 of the video disc of the copy such as comprising program or is supplied to client 414,416 via the electron channel of such as internet or Email.It is used on the personal computer 414,416 of user by user that composite building board is designed program.User designs one or more composite building board, and sends the design completed to manufacturer 420.Design can be printed, so that hard copy 418 is supplied to manufacturer 420.In a particular embodiment of the present invention, the design completed is uploaded to the central computer 406 being positioned at place of manufacturer 420.In another specific embodiment, design program software and for the device 408 of molded semicontinuous or continuous print foamed plastic part software between the design instruction that allowed of compatibility directly enter into device 408 by the connection to central computer.In another embodiment, design instruction is manually entered by device operator.Design software stores and grouped data based on concrete plate kind of design, and for manufacturing the most efficient operation of plate identification.Thus, software can be used as management tool, and with the work of simplification device operator, this work comprises the parts of the order of specifying and manufacturing plate and how operating means to design from a plate design variation to next plate.Trade method as shown in figure 40 decreases time and the cost of Design and manufacture customization building panel.
Detail with reference to specific embodiments of the invention describes the present invention.Be not intended to make the restriction that this details is considered to for scope of the present invention, scope of the present invention is determined by appended claims.

Claims (1)

1. a composite floor panels, described composite floor panels comprises:
Centerbody, the shape of described centerbody is parallelepiped substantially, and described centerbody is made up of expanded polymer matrix, and has relative two sides, top surface and relative basal surface;
One or more embedded floor joists, described embedded floor joists cross center's body between described relative two sides longitudinally extends, and there is first end, the second end and one or more inflation port, described first end is embedded in expanded polymer matrix, and there is the first cross member extended from first end, described first cross member contacts top surface or side's extension on the top generally, described the second end extends with the basal surface away from centerbody, and there is the second cross member extended from the second end, described inflation port is arranged in embedded floor joists between the first end and the basal surface of centerbody of embedded floor joists,
Wherein centerbody comprises the polymer substrate expanding through inflation port;
The space wherein limited by the basal surface of centerbody and the second end of embedded floor joists is suitable for holding utility lines; And
Wherein composite floor panels is positioned to generally perpendicular to structural wall and/or basis.
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CA2598315A1 (en) 2006-08-31
BRPI0607916A2 (en) 2010-03-23
MX2007010039A (en) 2007-09-21
WO2006091864A3 (en) 2007-09-07
AU2006216537B2 (en) 2011-04-14
CA2598315C (en) 2013-12-24
EP1851043A2 (en) 2007-11-07
WO2006091864A2 (en) 2006-08-31
AU2006216537B8 (en) 2011-08-11
CN102691372A (en) 2012-09-26
EP1851043A4 (en) 2014-05-14
MX364134B (en) 2019-04-12

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