Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
• • 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
  • E04B2/8605—Walls made by casting, pouring, or tamping in situ made in permanent forms without spacers

Definitions

• the present invention relates to the field of modular components employed for building structures, particularly of extruded thermoplastic components to be used as insulating and supporting members for the production on site or prefabrication of sound barrier panels used in buildings.
• Conventional systems for insulating building or wall structures or concrete panel prefabs are known, and these essentially consist of panels or layers of insulating materials such as for example expanded polystyrene or polyurethane foam, located within the cement or concrete casting.
• a major shortcoming of said known insulating systems is that they do not allow a total riddance of thermal bridges as prefabricated panels are at times interrupted by concrete ribs or support curbs. In correspondence with such interruptions there are often found to occur condenses and moulds. Moreover the polystyrene insulating panels may give rise to cracks, crevices and disjunction in and from the filling material wherein they are submerged.
• thermoplastic modular component type which is extruded and has a box-like cross-section, which is capable of being joined with other similar units in order to build complete walls, which is provided with a first series of hollow compartments that are capable of receiving the concrete casting on the site, as well as a second series of compartments that are located parallel to the first series and that are capable of hosting an insulating material.
• a known modular component forms a sort of formwork for the structure to build.
• This type of modular components known in the art are usually made of a thermoplastic material and by extrusion of synthetic resins that have previously been charged with glass fibres or alike.
• the material preferably used is of a fireproof type and the modular elements can be coated on their outside surfaces by layers of a high resistance plastic material in order to enhance its mechanical features.
• a drawback of said components for building structures is their relative complexity that involves the employment of rather complex extrusion processes and finishing processes for their production.
• the members In order to achieve a good partition of the concrete in the several compartments that the members comprise, mainly in case of very long modular elements, it is necessary to produce a certain number or openings in the separation walls in order to obtain a uniform distribution of the concrete during laying. All this contributes to the increase in the production costs of the components themselves.
• a further drawback of those building structures wherein said known modular member components are present is that there are found to occur discontinuities in correspondence with the areas joining adjacent panels, with the concurring likelihood to have infiltration on account of the fact that the concrete has in fact not a continuous surface.
• the most important object of the present invention is to propose a modular component for the production of wall structures whereby it is possible to obviate the above mentioned drawbacks, in particular that is easy to accomplish and put in place.
• a more specific object of the present invention is to propose a modular component for the insulation of wall structures that suppresses or reduces any thermal bridges that form between adjacent insulating panels, creating a wall structure that has substantially uniform insulating properties.
• a further object of the present invention is to propose a modular component to be used for building prefabricated panels or wall structures with a more pleasant aspect and features that result to be more easily acceptable by common people, as finishing at the surface levels where the plastic material is allowed to be evident can be avoided, in case this is what the customer aims at, and that makes it possible moreover to repair or restore the walls in case of impacts or damages.
• a modular component for the uniform insulation of wall structures characterised in that it comprises a substantially flat shaped main body having longitudinal end edges, said main body being provided with joining means located along said longitudinal edges, aimed at the mutual coupling with similar adjacent modular components so as to form a substantially continuous insulating panel that is devoid of thermal bridges, anchoring means being formed on said main body for its stable anchoring to the concrete or filling material volume which the wall structure within which the said component is found is provided.
• the modular component makes it possible to accomplish the production of wall structures having substantially uniform insulating properties and devoid of thermal bridges, these accountably being more cost-effective to be put in place, and, once finished, better looking and requiring a less committing maintenance.
• a method for the production of wall structures comprising insulating panels obtained by assembling modular components of the above mentioned type, which comprises the following steps: a) assembly of at least an insulating panel having a predetermined length and obtained by mutual coupling of a plurality of modular components according to one or more of claims 1 to 1 2; b) mounting a formwork consisting of a pair of side walls which are substantially parallel and insertion of said at least one insulating panel into a substantially intermediate position in between said side walls; c) Fitting of possible metal reinforcement members such as bars, washers or meshes in the portion or portions located between said at least one insulating panel and theformwork side walls. d) Concrete or another filling material casting into the interstices existing between said at least one insulating panel and the side walls of said formwork; e) Drying of the concrete; f) Disassembling of the formwork and exposure of the finished wall structure.
• Fig. 1 shows a perspective view of a first embodiment of a modular component according to the present invention, before it is put in place;
• Fig. 2 shows a perspective view of a second embodiment of a modular component according to the present invention before it is put in place
• Fig. 3 shows a perspective view of a third embodiment of a modular component according to the present invention before it is put in place
• Fig. 4 shows a perspective view of a portion of panel obtained from joining several modular components according to the present invention, before it is put in place;
• Fig. 5 shows a perspective view of a portion of panel obtained from joining several structural elements according to a second form of embodiment of the present invention before it is put in place;
• Fig. 6 shows a cross-sectional view of a portion of wall structure obtained from modular components according to the first form of embodiment shown in Figure 1 ;
• Fig. 7 shows a cross-sectional view of a portion of an alternative form of embodiment of the wall structure obtained from modular components according to the second form of embodiment illustrated in Figure 2;
• Fig. 8 is a cross-sectional view of a portion of a further alternative form of embodiment of the wall structure obtained from modular components according to the second form of embodiment shown in Figure 2;
• Fig. 9 shows a cross-sectional view of a third alternative form of embodiment of a portion of wall obtained from structural elements according to a third form of embodiment of the present invention after laying.
• Fig. 10 shows a cross-sectional view of a further embodiment of a modular component with sliding joining means
• Fig. 1 1 shows a cross-sectional view of a further embodiment of a modular component with sliding joining means
• Fig. 12 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 1 ;
• Fig. 1 3 shows a cross-sectional view of a further embodiment of a modular component with transversely fitting joining means
• Fig. 14 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 3;
• Fig. 1 5 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 3;
• Fig. 1 6 shows a cross-section view of a portions of wall structure incorporating several modular components shown in fig. 10
• Fig. 1 7 shows a cross-section view of a portion of wall structure incorporating several modular components shown in fig. 1 1 ;
• Fig. 1 8 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 2;
• Fig. 1 9 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 3;
• Fig. 20 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 14;
• Fig. 21 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 5;
• Fig. 22 shows a perspective view of a wal structure obtained from a panel whose portion is shown in Figure 4.
• a first form of embodiment is shown of the modular component according to the present invention, altogether identified by reference numeral 1 , essentially consisting of a portion of extruded profiled thermoplastic material, a PVC resin for example.
• modular component 1 may have a range of sections and sizes, depending on the type of building aimed at, and it can be cut to size when it is put in place on the building site or at the workshop before it is hauled to the site.
• modular component 1 comprises a substantially flat shaped central body 2 with its main sides 3, 4 substantially opposite to each other and parallel to a main structural plane H, joined by two end sides 5, 6 which are substantially perpendicular to sides 3, 4.
• faces 3, 4 and edges 5, 6 end up forming an interstice 2' that may be either be left empty of filled with an insulating material, a synthetic resin such as polystyrene or foamed polyurethane for example, so as to improve the overall thermal and/or sound insulating properties of the component.
• Each of the modular components 1 may be provided with respective joining means 7, 8 along its end edges 5, 6, for the mutual coupling with other similar components, identified with reference numerals 1 ', 1 ", so as to form an insulating panel P having indefinite size, according to the needs, and conferring a substantially uniform and continuous insulation, moreover free of thermal bridges in the joining area.
• joining means 7, 8 may consist of respectively male and female members that can be coupled by sliding.
• longitudinal protrusions 7' and 7" may be provided which are substantially opposite to each other and can be fitted into grooves 8', 8" by a sliding motion, said grooves being formed on sides 3, 4 and close to longitudinal end edge 6.
• joining means 7, 8 may have any complementary form whatsoever, provided that it is capable of mutually joining adjacent modular components 1 , 1 ', 1 " by engagement, along their respective longitudinal end edges.
• central body 2 is provided with members for a stable anchoring to the concrete mass or to any filling material whatsoever that makes up the wall structure.
• said anchoring members may be made of stiffening ribs 9, 10, 1 1 , 1 2 that extend towards the outside starting from one or both main sides 3, 4 of the modular component on planes that are substantially perpendicular to the H main structural plane and along a longitudinal direction.
• stiffening ribs 9, 10, 1 1 , 1 2 may advantageously be provided with longitudinal protrusions 1 3, 14, 14, 1 5 that extend on a plane that is substantially parallel to the main structural plane H, in order to improve the overall anchoring conditions and avoid any possible detachments of the concrete.
• stiffening ribs 9, 10 may be provided on just one side 3 of body 2, in case the opposite face is intended to be left exposed and completely devoid of stiffening ribs.
• stiffening ribs it is furthermore possible to provide a certain variable number of stiffening ribs according to the specific needs, as well as it is possible to vary the distance between stiffening ribs and their extension towards the outside.
• Figure 3 shows an alternative form of embodiment of component 1 wherein stiffening ribs 9 and 10 are regularly interrupted along their longitudinal direction, in order to achieve a better partition of the concrete during casting, in so doing avoiding the possibility to have bad looking voids on the wall.
• FIGS 4 and 5 schematically show portions of panels P each of them formed by the assembly of several modular components 1 , 1 ', 1 " that are joined by male and female joining means 7, 8. In such a way it is possible to join a predetermined number of modular components in a stable sort of way, in so doing obtaining a panel P having the desired width.
• Figure 6 shows a first alternative form of embodiment of a wall obtained by the joining of structural elements 1 , that further contain filling material at the interstice 2' in this specific alternative form of embodiment.
• Modular component 1 is placed between the side walls of a traditionalformwork which is not shown by the drawings, where concrete 1 7 is cast and reinforced with iron bars or meshes 1 8.
• a compact wall structure M having a homogeneous exterior look and furthermore devoid of outside plastic surfaces.
• Wall structure M that results from disassembling the formwork has a more pleasant exterior aspect and can be easily painted or finished as desired.
• wall insulation accomplished thanks to the air space or the insulating material placed in the interstice 2', effectively insulates the two portions of concrete 1 7 and 1 7', avoiding any thermal bridge whatsoever in correspondence with the panel P component joints.
• the occurrence of the anchoring elements and of the relative protrusions allows to position the insulating panel P between the formwork walls in a handy and precise fashion.
• a further advantage of the present invention is that there is found to arise the possibility to resort to lower quality materials as after putting in place none of the portions of the members can be seen from the outside. Moreover, such a type of prefabricated panels or wall structures are more easily accepted by common people because they are more similar to traditional building structures.
• Figure 7 shows a further operating alternative form of embodiment of a wall structure M wherein side 3 of body 2 is the surface of insulating panel P and is bound to remain outside, whereas the opposite face 4 is bound to cooperate with the concrete.
• a solution may turn out to be advantageous when some of the features of the thermoplastic materials are to be exploited, such as endurance to weathering, in order to obtain the outside wall of a building with very high and fine surface finishing and also provided with a stable colouring.
• a formwork made of just one exchangeable wall may be used, whereas the second parallel wall is made of the insulating panel P itself that is useful in containing and constraining the concrete.
• This alternative form of embodiment is very advantageous even for the production of covering surfaces to be used in buildings or roofs of the ventilated or insulated types.
• the third alternative operating form of embodiment shown in Figure 8 allows to obtain a wall structure M having both exterior surfaces consisting of the outside surfaces of two panels P, P' formed by respective modular components.
• the concrete is placed into the interstice formed by the two panels P, P' and it acts as a fixed form work.
• FIG. 9 The fourth alternative operating form of embodiment shown in Fig. 9 is a solution to all those cases where the wall structure does not necessarily have to have extremely enhanced insulating features.
• panels P" are formed by joining components 20 that are substantially plate shaped rather than box shaped. Furthermore side 2 of panel P" which is turned towards the outside consists of the very exterior surface of modular components 20.
• Fig. 10 to 1 2 show several embodiment of modular component with one or two layers of insulating material 2' in which the joining means are shaped so as to be slidably coupled to each other along a direction that is substantially parallel to the longitudinal edges of the component.
• Fig. 13 to 16 show several embodiments of modular components with one or two layers of insulating material 2' in which the joining means are shaped so as to be transversely coupled to each other along a direction that is substantially perpendicular to the longitudinal edges of the component.
• thermoplastic materials whose properties comprise endurance to ageing, to fire or to other aggressive agents.
• structural elements may be manufactured with several different sizes and can be employed both in their horizontal and vertical position, in accordance with the specific type of building to be manufactured.
• a panel P is assembled first by mutually joining several modular thermoplastic components 1 in accordance with the present invention. If necessary panel P is cut down to size.
• a formwork which is known in the art is then built, said formwork having plastic, wood or metal walls, wherein assembled panel P is inserted employing the components 1 of which above.
• metal reinforcements are then placed, said metal frames being of the reinforced-concrete rod or mesh types in the space between panel P and the formwork walls, and the concrete is then cast into said space. The time necessary for drying is then allowed after which the formwork is disassembled. At the end of this process a wall or wall member is obtained such as that shown in figure 6.
• the wall structure has both walls consisting of panels P', P" obtained by the assembly of components 1 according to the present invention, in comparison with the above described method, there is found to arise the difference in that the formwork walls both consist of the same panels P', P", therefore at the end of the process there is no need for theformwork to be disassembled, as it eventually integrates to become a portion of the wall structure.
• the process for the production of prefabricated concrete panels comprising modular thermoplastic components may be the following.
• a first layer of concrete is first laid on the planes or tables traditionally used for the production of prefabricated panel, preferably of a vibrated type, and placed horizontally. After that a metal mesh or another suitable reinforcement material is laid horizontally on the concrete layer.
• a third concrete layer is then cast, said concrete layer having such a minimum thickness as to allow covering of supporting ribs 9, 10, 1 1 , 1 2. After that the mesh or other concrete reinforcement members are placed and the surface is covered with the amount of concrete needed in order for the desired thickness of the prefabricated component to be achieved.
• the upper side of the panel is then finished on its surface, resorting to methods known in the art. After the concrete has sufficiently set, the panel is removed from the table.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Insulating Bodies (AREA)
• Manufacturing Of Electrical Connectors (AREA)

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• 1999
  • 1999-05-24 IT IT1999VI000106A patent/IT1307442B1/it active
• 2000
  • 2000-05-19 EP EP00927633A patent/EP1180184B1/de not_active Expired - Lifetime
  • 2000-05-19 TR TR2002/00115T patent/TR200200115T2/xx unknown
  • 2000-05-19 DE DE60022643T patent/DE60022643D1/de not_active Expired - Lifetime
  • 2000-05-19 AT AT00927633T patent/ATE304635T1/de not_active IP Right Cessation
  • 2000-05-19 AU AU46022/00A patent/AU4602200A/en not_active Abandoned
  • 2000-05-19 WO PCT/IB2000/000674 patent/WO2000071828A1/en not_active Ceased

Non-Patent Citations (1)

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