EP2956595A2 - Machine and method for manufacturing a prefabricated wall and a prefabricated wall - Google Patents

Machine and method for manufacturing a prefabricated wall and a prefabricated wall

Info

Publication number
EP2956595A2
EP2956595A2 EP14714342.4A EP14714342A EP2956595A2 EP 2956595 A2 EP2956595 A2 EP 2956595A2 EP 14714342 A EP14714342 A EP 14714342A EP 2956595 A2 EP2956595 A2 EP 2956595A2
Authority
EP
European Patent Office
Prior art keywords
ribs
planks
planking
dovetail
machine
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.)
Withdrawn
Application number
EP14714342.4A
Other languages
German (de)
French (fr)
Inventor
Giorgio Bertagnolli
Federico Bertagnolli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BERTAGNOLLI AFG S.R.L.
Original Assignee
Bertagnolli Afg Di Giorgio Bertagnolli & C Sas
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Bertagnolli Afg Di Giorgio Bertagnolli & C Sas filed Critical Bertagnolli Afg Di Giorgio Bertagnolli & C Sas
Publication of EP2956595A2 publication Critical patent/EP2956595A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • E04C2/10—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/12—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of solid wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/0013—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles
    • B27M3/002—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by oblong elements connected at their ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/0013—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles
    • B27M3/0026—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by oblong elements connected laterally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/0013—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles
    • B27M3/008—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by bar or grill connections
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/386—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood
    • 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
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/10—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of wood
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels

Definitions

  • the present invention relates in general to a construction method for manufacturing a prefabricated wall and to a prefabricated wall. Specifically, it relates to a construction method for manufacturing prefabricated load-bearing wooden walls for civil buildings, by means of a machine that is a subject of the present disclosure.
  • a prefabricated wall obtainable by the construction method is a subject of the present disclosure as well.
  • the aim is at manufacturing a structure that is statically efficient, versatile and that can be made with solid timber, without glue and with a minimum amount of timber, labour and energy.
  • the object of the present invention is the construction of versatile walls, without using adhesives and requiring ironmongery for the sole purpose of securing on site, which have a toughness both real and perceived, which can be manufactured with lower cost, simplifying the manufacturing and improving thermal, acoustic and fire resistance performances in comparison to other systems.
  • the machine and the method that are subjects of the present disclosure relate to the manufacturing of a prefabricated wooden wall, which is composed by two planking boards of vertical planks and by horizontal ribs.
  • the planks and the ribs are of wood.
  • the two planking boards are spaced apart and connected to each other by a dovetail joint system: the ribs are provided with dovetail tenons and the planks of the planking boards are provided with corresponding dovetail mortises to receive respective dovetail tenons of the ribs.
  • the two planking boards are parallel to each other.
  • a machine according to the present disclosure comprises:
  • an adjustable anchoring system for anchoring the ribs to the fixed head
  • the machine is configured to receive and lock the ribs between the anchoring system and the limit stop bar.
  • the device for alignment and initial insertion is configured to guide the initial insertion of the planks onto first ends of the ribs, in such a way that the dovetail mortises of a plank receive corresponding dovetail tenons of the ribs.
  • the longitudinal pushing device is configured to advance one or more planks along the ribs towards the limit stop bar: in this manner, the planks are inserted onto the ribs and, plank by plank, the respective planking board is assembled.
  • Such a machine is useful for implementing, in a simple way, the method for manufacturing the wall, which basically provides for the steps of:
  • the ribs are positioned and anchored between the anchoring system and the limit stop bar of the above-described machine, in such a way that the first ends of the ribs are constrained to the anchoring system and the second ends of the ribs rest on the limit stop bar. Moreover, the positioning of the planks into the upper joint and into the lower joint is carried out by the longitudinal pushing device.
  • the ribs secured to the machine serve as a support for assembling the wall, both when composing the first planking board and when composing the second planking board.
  • the manufacturing of the wall is faster in comparison with the prior art and the need to move the wall under construction is avoided: the entire wall is constructed on the machine using the ribs as support and adjuster for the planks to be inserted.
  • the longitudinal members are configured to provide a rest to the planks during the construction of the first planking board or lower planking board, while the ribs themselves provide a rest to the planks during the construction of the second planking board or upper planking board.
  • the length of the wall to be obtained is set by the length of the ribs.
  • the height of the wall to be obtained is set by the length of the planks.
  • the manufacturing of the wall is simpler and has less friction to overcome in comparison with a method that provides for inserting the ribs onto planks that are kept steady.
  • the ribs are secured to the machine (in particular, to the anchoring system) by means of devices (for example: pegs, screws, bolts, threaded rods) that will be used later to secure the walls to each other on site.
  • devices for example: pegs, screws, bolts, threaded rods
  • a stratification of materials chosen for isolation and / or insulation i.e., materials for thermo-acoustic insulation), for air tightness, for fire resistance or for thermal inertia are laid between the ribs (for example, by placing them on the planks of the first planking board) after composing the first planking board and before composing the second planking board.
  • materials chosen for isolation and / or insulation i.e., materials for thermo-acoustic insulation
  • air tightness for fire resistance or for thermal inertia
  • fire resistance or for thermal inertia are laid between the ribs (for example, by placing them on the planks of the first planking board) after composing the first planking board and before composing the second planking board.
  • Such materials are intended to stay in the space between the two planking boards. This is useful for allowing a broad versatility of performances for the wall.
  • each calibration milling defines an abutment with a respective rib and, specifically, it is made around a respective mortise.
  • each calibration milling is made on a non-planed surface of the plank and is recessed in relation to the remaining non-planed surface of the plank.
  • the calibration millings are made simultaneously with the dovetail mortises of the plank.
  • the dovetail mortises are made with such a depth that the dovetail tenon has a smaller depth than the corresponding dovetail mortise, so as to leave a clearance between the tenon and the mortise, the clearance determining a non- contact point between the plank and the rib.
  • the adjustable support or limit stop bar rests on the longitudinal members and is adapted to support the second ends of the ribs.
  • the adjustable support serves as a rest for the second ends of the ribs and as a limit stop for the insertion of the planks onto the ribs.
  • the position of the adjustable support can be set and adjusted according to the length of the ribs. This is useful for allowing the machine to be adapted to the length of the wall to be obtained: the support is adjusted and positioned according to the length of the ribs and, in addition to supporting the second ends of the ribs, it defines the limit stop without any need for further machine settings.
  • the adjustable support comprises a device for locking the ribs. This is useful for preventing the ribs from accidentally moving during the manufacturing of the wall.
  • the device for alignment and initial insertion comprises wedge-shaped guides that facilitate the multiple insertion of the mortises into the corresponding tenons. This is useful for an easy insertion of the planks onto the ribs secured to the machine.
  • the device for alignment and initial insertion comprises lower wedge-shaped guides and upper wedge-shaped guides; the lower wedge-shaped guides are configured to guide the initial insertion of the planks of the lower planking board and the upper wedge-shaped guides are configured to guide the initial insertion of the planks of the upper planking board.
  • the anchoring system is height adjustable. This is useful for adapting the machine to the thickness of the planks of the lower planking board.
  • the longitudinal pushing device is configured to sequentially advance one or more planks of a first planking board or lower planking board and one or more planks of a second planking board or upper planking board.
  • the same longitudinal pushing device manufactures the first planking board by pushing the respective planks one after the other (singly or as groups of planks) and, after completion of the first planking board, it manufactures the second planking board by pushing the respective planks one after the other (singly or as groups of planks).
  • the longitudinal pushing device comprises appendages adapted to prevent the planks from vertically escaping because of the eccentric force applied; the longitudinal pushing device comprises a height- adjustable crosspiece adapted to push the planks.
  • the appendages are used during the manufacturing of the lower planking board, whereas the crosspiece is used during the manufacturing of the upper planking board.
  • the anchoring system comprises abutment surfaces for receiving end faces of the ribs, said abutment surfaces having a tilt that is non- orthogonal with respect to an insertion direction or longitudinal direction of the ribs.
  • said tilt is comprised between 5 degrees and 10 degrees with respect to an orthogonal tilt, i.e. with respect to a plane perpendicular to the insertion direction or longitudinal direction of the ribs.
  • each rib has a first end with an end face that is tilted relative to a plane perpendicular to the longitudinal direction of the rib and each rib has a second end having a tilted recess adapted to receive the end face of a corresponding rib of a second prefabricated wooden wall that is arranged at right angle with the first prefabricated wooden wall.
  • the present disclosure relates to a construction method of a prefabricated wooden wall, a machine for manufacturing thereof and accessory devices.
  • the wooden wall is composed by the interlocking joining of two vertical load-bearing planking boards, which are spaced apart and joined by suitably shaped ribs, to achieve a strong structure having a cavity that can be used for inserting insulating material and as a technical compartment.
  • the method allows to use sawn timber without the need for planing; the assembling is done without glue, with the consequent ecological advantages and cost savings.
  • the assembling machine makes use of the ribs as a support to the manufacturing and operates by inserting and pushing the planks into the interlocking joints of the ribs themselves.
  • the so-obtained walls can be used directly or with the addition of internal and / or external clothing.
  • each embodiment of the subject of the present disclosure may have one or more of the advantages listed above; in any case it is not required for each embodiment to have simultaneously all the advantages listed.
  • FIG. 1 shows an axonometric cutaway view of a wall according to the present disclosure
  • FIG. 2 shows an axonometric view of a plank that belongs to the wall of Figure 1 ;
  • FIG. 3 shows an axonometric cutaway view of a variant embodiment of a wall according to the present disclosure
  • Figures 4A and 4B show axonometric views of components that belong to the wall of Figure 3;
  • FIG. 5 to 8 show sectional and axonometric views of an interlocking system according to the present disclosure and of the components thereof;
  • FIG. 9A to 9D show sectional views of the interlocking system for variant embodiments of a wall according to the present disclosure
  • FIG. 10 shows an axonometric view of a machine according to the present disclosure
  • FIG. 11 , 12 and 13 show details of an anchoring and aligning system of the machine of Figure 10;
  • Figure 16A shows a component of the pusher of Figure 16.
  • FIG. 17 to 19 show steps of an assembling method for a wall according to the present disclosure
  • FIG. 20 shows a corner connection between two walls according to the present disclosure
  • FIG. 21 A and 21 B show details of a connecting device of a wall according to the present disclosure
  • FIG. 21 B shows details of a connecting device of a wall according to the present disclosure
  • FIG. 22 and 23 show a detail of a variant embodiment of the anchoring and aligning system of the machine of Figure 10, with a rib that is shown released and anchored, respectively.
  • FIGS. 24 to 24A show an axonometric view and end details of a rib to be used with the anchoring and aligning system of Figure 22;
  • Figure 25 shows a corner connection between two ribs of Figure 24
  • FIG. 26 shows a corner connection between two walls including ribs of Figure 24;
  • FIG. 27 and 27A show an axonometric view and a details of two ribs that are connected to each other in an aligned condition.
  • the purpose is to compose a prefabricated wall 1 with two planking boards 2 of vertical planks 3.
  • the planking boards 2 are joined and spaced apart from each other by ribs 4, having a length equal to that of the wall, suitably shaped and having tenons 10 with a dovetail profile 5 on the sides.
  • two opposite sides of each rib 4 have respective tenons 10 that extend along the entire length of the rib 4; the tenon 10 on one side is intended to engage mortises 1 1 of the planks 3 of a planking board 2, the tenon 10 on the other side is intended to engage mortises 1 1 of the planks 3 of the second planking board 2.
  • the tenons 10 and the mortises 1 1 have dovetail profiles and compose a dovetail joint system.
  • the planking boards 2 and their planks 3 have a load-bearing function for the wall 1.
  • the milling 7 allows the use of non-planed wooden planks 3.
  • the calibration milling 7 is made on a surface 70 of the plank 3 that is intended to face the other planking board; the calibration milling 7 is recessed in relation to the remaining surface 70. Since the contact between the rib 4 and the surface of the plank 3 is confined to the calibration milling 7, the remaining surface 70 can be non-planed or with an irregular surface, without this having any effect on the dovetail joint system;
  • ⁇ shaped ribs 12 with grooves 13, which are useful for positioning and / or laying insulating materials 19 and / or various materials 20 and / or other materials and for leaving empty cavities 14 inside the two planking boards 2.
  • the joining elements 15, 16 of the two vertical load-bearing planking boards 2 have dovetail joints and a profile adapted to close a respective horizontal side of the wall 1.
  • Figures 1 to 4B show the elements of exemplary walls denoted by reference number 1 : planking boards 2, a single milled plank 3, ribs of various types 4, 12, 15, tenons 10 with dovetail 5, cavity 6, calibration milling 7.
  • Figures 5 to 8 show sectional details and highlight the points of contact 8 between tenon 10 and mortises 1 1 and the clearance 9 that results from the smaller depth of the tenon 10 in comparison with the mortise 1 1.
  • the calibration milling on the planks is highlighted as well and is denoted by reference number 7; the trace of such a milling 7 will not be uniform if it is made on rough planks.
  • the axonometric-view magnification shows the dovetail joint in details.
  • Figures 9A to 9D show some types of ribs 4, 12 for various compositions and stratifications of accessory materials 19, 20, in addition to horizontal closing ribs 15, 16 for the wall 1 , usable both at the bottom and at the top.
  • ribs 12, 15, 16 there may be longitudinal grooves 13 and / or abutments to position and / or lay various types of stratification of insulating materials and / or other materials and / or to leave empty cavities inside the two planking boards.
  • the wall 1 has cheaper costs for materials and better thermal performances than a multiple-planking system, the overall thickness being equal.
  • the load-bearing element is not at the centre of the wall, but at the sides.
  • the load-bearing function is performed by the planking boards 2.
  • a fourth aspect is the possibility to compose various stratifications inside the structure, resulting in a broad versatility of performances of the physical features.
  • a final important aspect is the perception of toughness that the wall shows from both a visual and a tactile point of view.
  • the ribs 4, 12, 15, 16 and the planks 3 required for construction of the wall 1 are prepared in advance.
  • a machine 90 that is shown in a preferred (but not sole) embodiment in Figures 10 to 19, is used for composing the wall.
  • the machine 90 includes a base with runways 21 and a fixed head 22, two longitudinal side members 23 with supports at the ends, an adjustable support 24 anchored to the head 22, a device 25 for connecting / anchoring the ribs, an adjustable system of alignment 26 and centring 27 of the dovetail joints, a pushing system 28 with a stroke over the entire length of the base and provided with appendages 29 for the insertion of the lower planking and with a height-adjustable crosspiece 30 for the insertion of the upper planking, a limit stop bar 31 with a device 32 of locking to the ribs, provided with an adjuster 33 for limit stop of the upper planking.
  • the ribs are made firmly joined to the base by means of such devices, while the pusher 28, moving on the base itself, can exert the force required to insert one or more planks at a time into the joints as far as the limit stops, which, blocked by a coupling 32 to the ribs, correctly position the first plank of both the lower planking and the upper planking.
  • an exemplary embodiment of a machine for assembling the walls comprises a base with runways or sliding guides 21 and with a head 22 firmly joined to the base, at an end of the base itself.
  • An adjustable system for anchoring the ribs to the fixed head is attached to the head 22: this is a height-adjustable support on which the adjustable anchoring devices for the ribs and a system of alignment 26 and centring 27 of the dovetail joints, which allow the initial insertion of the planks 3, are located.
  • the alignment and centring system includes wedge-shaped guides 27 that facilitate the multiple insertion of the mortises into the respective tenons.
  • the pusher 28 (or longitudinal pushing device) slides on the base; by means of an adjustable device 29, the pusher 28 positions the planks of the lower planking board as far as the limit stops 31 , which have an adjustable raised support.
  • the pusher 28 slides along the runways or sliding guides 21.
  • the pusher 28 has a reciprocating movement and, in each stroke towards the limit stop 31 , pushes one or more planks to the limit stop or to the planks already positioned in the previous stroke.
  • planking board In the present disclosure, reference is made to a lower planking board and to an upper planking board: it should be understood that the terms “lower” and “upper” here refer to the position of the wall on the machine during the assembling. These planking boards will be vertical when the wall is completed and installed on site.
  • the sequence of operations for the composition of the wall is preferably, but not exclusively, as follows.
  • the ribs of the various types 4, 12, 15, 16, which have the length of the wall to be obtained, are secured to the anchorages 26 with a first end 17 thereof and rest with the other end 18 on the limit stop bar 31 , which in turn rests on the longitudinal members 23. Therefore, the ribs of the wall are constrained with a first end 17 thereof to the fixed part of the machine 90, while the second end 18 of the ribs is supported by a support 31 resting on the longitudinal members 23.
  • the support / limit stop 31 with the coupling 32 is a device serving as a support for an end of the ribs and as a limit stop for the insertion of the planks.
  • the ribs 4, 12, 15, 16 are used to set the limit stop 31 of the positioning of the planks 3; in fact, the limit stop 31 is displaceable and adjustable according to the length of the ribs.
  • the ribs are provided with connecting devices 25, 25a, 25b, 25c having the function of constraining and positioning the ribs (therefore, the wall being constructed) to the anchorages 26; the same devices 25, 25a, 25b, 25c have the second function of securing the obtained walls to each other, once installed on site.
  • the ribs act as support and adjuster for the composition of the walls by means of the connecting devices 25 that will serve to secure them together when installed on site.
  • planks 3 previously milled, are positioned on the longitudinal members 23, onto the wedge-shaped sledges 27, and are advanced by the pusher 28 towards the opposite end of the ribs, where the limit stop bar 31 stops them in the desired position.
  • the pusher 28 is brought back and the cycle of insertion of the planks 3 of the first planking board is repeated until the first planking board is completed.
  • the pusher 28 positions one or more lower-planking-board planks at a time into the dovetail joint of the ribs (i.e., into the lower tenons), up to sequentially compose a first planking board 2 of the wall 1.
  • Figure 17 shows the machine 90 with the ribs 4 of the wall that are secured with one end 17 thereof to the anchoring systems 24 to the head and with the second end 18 resting on the limit stop bar 31 , to which it is locked by the device 32; the pusher 28 is pushing two planks 3, resting on the longitudinal members 23, towards the limit stop 31.
  • the appendages 29 prevent any lifting of the plank due to the eccentric force applied by the pusher.
  • the next step is to lay the stratification of materials chosen for isolation, insulation, air tightness, fire resistance, thermal inertia and so on, onto the planking and between the ribs.
  • Figure 18 shows the wall with the completely-made lower planking board and with the insulation panels 20 during manual positioning.
  • the adjusters and the wedge-shaped sledges 27 are adjusted for the second planking board, the appendages 29 are replaced by the crosspiece 30 of the pusher (adjusted at the suitable height), a limit stop 33 for the upper planking is adjusted.
  • the planks 3 are positioned at the mouth of the wedge-shaped sledges 27 and the sequential composition of the second planking board is carried out.
  • the pusher 28 positions one or more upper-planking-board planks at a time into the dovetail joint of the ribs (i.e., into the upper tenons), going through the alignment devices, up to sequentially compose the second planking board 2 of the wall 1.
  • Figure 19 shows the pusher 28 that is positioning two planks 3 of the upper planking board by means of the crosspiece 30; the upper planking board is partly composed from the limit stops 33.
  • the ribs 4 of the whole length of the wall are shown; the ribs will be cut in correspondence of the hole for a door in the completed wall, except for the bottom rib 15 that can be cut in the installed wall, thus enjoying a greater toughness during transport and assembly.
  • the planks can be cut to measure and pushed as a group, but the ribs 4 are required to be intact; the ribs will be cut when the wall is completed.
  • the bottom rib 15 (which will be the lower rib in the wall installed on site) can be left intact until the installation of the wall on site; the bottom rib will be cut later.
  • the ribs 4, 12, 15, 16 are used as a support for the assembling of the wall itself in the machine 90.
  • the so-obtained wall can be used directly or it can be clothed both inside and outside.
  • the planking boards can be rough or planed or prepared with male / female interlocking joints or with a connecting core.
  • Figure 20 shows the right angle between two walls 1 connected by the connecting devices 25, which are the same used for anchoring the ribs to the machine 90.
  • the device for alignment 26 and initial insertion 27 has abutment surfaces 270 for the first ends 17 of the ribs, wherein these abutment surfaces 270 are at an oblique angle, i.e. they have a non- orthogonal tilt with respect to the insertion direction, i.e. with respect to the longitudinal direction of the wedge-shaped guides 27 and to the longitudinal direction 400 of the ribs 4, 12, 15, 16.
  • each wedge-shaped guide 27 has a tilted flat face that is an abutment surface 270 against which an end face 40 of the respective rib abuts.
  • each abutment surface 270 forms an angle A ranging between 5 degrees and 10 degrees with respect to a plane perpendicular to said insertion direction or longitudinal direction 400 ( Figure 22).
  • the rib 4 has an end face 40 that, instead of being perpendicular to the longitudinal direction 400, is tilted with an angle A with respect to perpendicular. Therefore, at the first end 27, a first tenon 10 is longer than the second tenon 10.
  • the end face 40 is in contact with the whole abutment surface 270 and then a stable positioning of the rib is obtained.
  • This can be further improved by providing protrusions 260 that protrude from the alignment device 26 towards the sides of the rib 4: when the rib 4 is in position, its sides are in contact with the protrusions 260 that prevent unwanted movements (for example: side movements, rotations and inclinations) of the rib 4 with respect to the anchoring system 24.
  • the second ends 18 of the ribs are processed to make a tilted recess 45 or tilted seat having the same tilt A ( Figures 24, 24A).
  • the tilted end faces 40 of the ribs of the first wall go into the recesses 45 of the ribs of the second wall ( Figures 25 and 26), to obtain a corner connection that is stronger thanks to the contrast between the tilted surfaces, wood against wood, and to a step 46 of the recess 45 against which the other rib abuts.
  • the connecting device 25 can also be used to join together two ribs in an aligned position instead of forming a corner.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Load-Bearing And Curtain Walls (AREA)
  • Rigid Containers With Two Or More Constituent Elements (AREA)
  • Toys (AREA)

Abstract

The present disclosure describes the construction method, the manufacturing machine (90) and accessory devices of a prefabricated wooden wall (1), composed by the interlocking connection of two vertical load-bearing planking boards (2), spaced apart and joined by suitably shaped ribs (4, 12, 15, 16), to achieve a strong structure having a cavity (6) to be used for inserting insulating material (20) and as a technical compartment. The method allows to use sawn timber without the need for planing, and the assembling is done without glue, with the consequent ecological advantages and cost savings. The assembling machine (90) makes use of the ribs (4, 12, 15, 16) as a support to the manufacturing and operates by inserting and pushing the planks (3) into the interlocking joints of the ribs themselves (4, 12, 15, 16). The so-obtained walls (1) can be used directly or with the addition of internal and / or external clothing.

Description

MACHINE AND METHOD FOR MANUFACTURING
A PREFABRICATED WALL AND A PREFABRICATED WALL
DESCRIPTION
The present invention relates in general to a construction method for manufacturing a prefabricated wall and to a prefabricated wall. Specifically, it relates to a construction method for manufacturing prefabricated load-bearing wooden walls for civil buildings, by means of a machine that is a subject of the present disclosure. A prefabricated wall obtainable by the construction method is a subject of the present disclosure as well. The aim is at manufacturing a structure that is statically efficient, versatile and that can be made with solid timber, without glue and with a minimum amount of timber, labour and energy.
Description of prior art
In the field of wooden constructions, the systems that are currently being used more and that are well suitable for prefabrication are the frame-type ones and the glued- stratified-plank-type ones (cross-lam). There are other systems using stratified planks, assembled with nails, dowels or dovetail joints, but these are less common.
Finally, there are walls with discontinuous elements, such as wooden bricks or universal modular units, which are essentially niche products.
The technique of dovetail-type mechanical assembling is used in both woodwork and carpentry and it boasts an ancient tradition. Original solutions pertaining to the architecture of walls with dovetail joints have recently been developed; for example, reference is made to documents FR2930959A1 and EP1734200A1.
Technical problem to be solved
In the present case, however, are here explained a method, devices and a machine for manufacturing a wall with elements that are connected in a dovetail manner according to a mode that is defined as a "bilateral dovetail joint" in technical literature (Ref. Giuseppe Pierasca, "II legno e I'arte di costruire mobili e serramenti", Hoepli Editore 1985, page 179 figure 279).
The object of the present invention is the construction of versatile walls, without using adhesives and requiring ironmongery for the sole purpose of securing on site, which have a toughness both real and perceived, which can be manufactured with lower cost, simplifying the manufacturing and improving thermal, acoustic and fire resistance performances in comparison to other systems.
General description of the invention
This object and further ones are achieved by providing a machine for manufacturing a prefabricated wooden wall according to claim 1 and by applying a method for manufacturing a prefabricated wooden wall according to claim 13, as well as by a prefabricated wooden wall according to claim 21.
Particular embodiments of the subject of the present disclosure are defined in the corresponding dependent claims.
The machine and the method that are subjects of the present disclosure relate to the manufacturing of a prefabricated wooden wall, which is composed by two planking boards of vertical planks and by horizontal ribs. The planks and the ribs are of wood. The two planking boards are spaced apart and connected to each other by a dovetail joint system: the ribs are provided with dovetail tenons and the planks of the planking boards are provided with corresponding dovetail mortises to receive respective dovetail tenons of the ribs. Basically, the two planking boards are parallel to each other.
A machine according to the present disclosure comprises:
- a base with runways, equipped with a fixed head;
- two longitudinal members or side supports, which extend with whole length at sides of the base;
- an adjustable anchoring system for anchoring the ribs to the fixed head;
- a longitudinal pushing device that is slidable along the runways;
- a device for alignment and initial insertion of the planks of the planking board;
- an adjustable support that is a limit stop bar.
The machine is configured to receive and lock the ribs between the anchoring system and the limit stop bar. The device for alignment and initial insertion is configured to guide the initial insertion of the planks onto first ends of the ribs, in such a way that the dovetail mortises of a plank receive corresponding dovetail tenons of the ribs.
The longitudinal pushing device is configured to advance one or more planks along the ribs towards the limit stop bar: in this manner, the planks are inserted onto the ribs and, plank by plank, the respective planking board is assembled.
Such a machine is useful for implementing, in a simple way, the method for manufacturing the wall, which basically provides for the steps of:
- providing a plurality of ribs, equipped with dovetail tenons;
- providing a plurality of planks, equipped with dovetail mortises;
- positioning and anchoring the ribs to an assembling machine;
- positioning one or more planks at a time into a lower dovetail joint (i.e., into lower tenons) of the ribs, up to sequentially compose a first planking board or lower planking board of the wall;
- positioning one or more planks at a time into an upper dovetail joint (i.e., into upper tenons) of the ribs, up to sequentially compose a second planking board or upper planking board of the wall.
Specifically, the ribs are positioned and anchored between the anchoring system and the limit stop bar of the above-described machine, in such a way that the first ends of the ribs are constrained to the anchoring system and the second ends of the ribs rest on the limit stop bar. Moreover, the positioning of the planks into the upper joint and into the lower joint is carried out by the longitudinal pushing device.
Basically, the ribs secured to the machine serve as a support for assembling the wall, both when composing the first planking board and when composing the second planking board. The manufacturing of the wall is faster in comparison with the prior art and the need to move the wall under construction is avoided: the entire wall is constructed on the machine using the ribs as support and adjuster for the planks to be inserted.
According to a specific embodiment, the longitudinal members are configured to provide a rest to the planks during the construction of the first planking board or lower planking board, while the ribs themselves provide a rest to the planks during the construction of the second planking board or upper planking board.
The length of the wall to be obtained is set by the length of the ribs. The height of the wall to be obtained is set by the length of the planks.
Thanks to the ribs that are kept steady and with a right distance between them, and to the individual planks that are inserted onto all the ribs at once by a movement of the longitudinal pushing device, the manufacturing of the wall is simpler and has less friction to overcome in comparison with a method that provides for inserting the ribs onto planks that are kept steady.
According to an embodiment, the ribs are secured to the machine (in particular, to the anchoring system) by means of devices (for example: pegs, screws, bolts, threaded rods) that will be used later to secure the walls to each other on site.
According to a mode of carrying out the method, a stratification of materials chosen for isolation and / or insulation (i.e., materials for thermo-acoustic insulation), for air tightness, for fire resistance or for thermal inertia are laid between the ribs (for example, by placing them on the planks of the first planking board) after composing the first planking board and before composing the second planking board. Such materials are intended to stay in the space between the two planking boards. This is useful for allowing a broad versatility of performances for the wall.
According to a mode of carrying out the method, calibration millings are made on the planks before positioning thereof. The calibration millings calibrate the planks at points that are intended for contacting the respective ribs: each calibration milling defines an abutment with a respective rib and, specifically, it is made around a respective mortise.
This is useful for allowing the use of non-planed planks and for restricting the processing of the plank surface just to the calibration millings, optionally leaving unaltered the remaining part of the plank surface.
Specifically, each calibration milling is made on a non-planed surface of the plank and is recessed in relation to the remaining non-planed surface of the plank.
In particular, the calibration millings are made simultaneously with the dovetail mortises of the plank.
Furthermore, the dovetail mortises are made with such a depth that the dovetail tenon has a smaller depth than the corresponding dovetail mortise, so as to leave a clearance between the tenon and the mortise, the clearance determining a non- contact point between the plank and the rib.
According to an embodiment of the machine, the adjustable support or limit stop bar rests on the longitudinal members and is adapted to support the second ends of the ribs. The adjustable support serves as a rest for the second ends of the ribs and as a limit stop for the insertion of the planks onto the ribs. In particular, the position of the adjustable support can be set and adjusted according to the length of the ribs. This is useful for allowing the machine to be adapted to the length of the wall to be obtained: the support is adjusted and positioned according to the length of the ribs and, in addition to supporting the second ends of the ribs, it defines the limit stop without any need for further machine settings.
Specifically, the adjustable support comprises a device for locking the ribs. This is useful for preventing the ribs from accidentally moving during the manufacturing of the wall.
According to an embodiment, the device for alignment and initial insertion comprises wedge-shaped guides that facilitate the multiple insertion of the mortises into the corresponding tenons. This is useful for an easy insertion of the planks onto the ribs secured to the machine.
According to a specific embodiment, the device for alignment and initial insertion comprises lower wedge-shaped guides and upper wedge-shaped guides; the lower wedge-shaped guides are configured to guide the initial insertion of the planks of the lower planking board and the upper wedge-shaped guides are configured to guide the initial insertion of the planks of the upper planking board.
According to an embodiment, the anchoring system is height adjustable. This is useful for adapting the machine to the thickness of the planks of the lower planking board.
According to an embodiment, the longitudinal pushing device is configured to sequentially advance one or more planks of a first planking board or lower planking board and one or more planks of a second planking board or upper planking board. In other words, the same longitudinal pushing device manufactures the first planking board by pushing the respective planks one after the other (singly or as groups of planks) and, after completion of the first planking board, it manufactures the second planking board by pushing the respective planks one after the other (singly or as groups of planks).
According to specific embodiments, the longitudinal pushing device comprises appendages adapted to prevent the planks from vertically escaping because of the eccentric force applied; the longitudinal pushing device comprises a height- adjustable crosspiece adapted to push the planks. In particular, the appendages are used during the manufacturing of the lower planking board, whereas the crosspiece is used during the manufacturing of the upper planking board. These features are useful for a better functionality and a better adaptability of the pushing device, also according to the size of the wall to be obtained.
According to an embodiment, the anchoring system comprises abutment surfaces for receiving end faces of the ribs, said abutment surfaces having a tilt that is non- orthogonal with respect to an insertion direction or longitudinal direction of the ribs. Specifically, said tilt is comprised between 5 degrees and 10 degrees with respect to an orthogonal tilt, i.e. with respect to a plane perpendicular to the insertion direction or longitudinal direction of the ribs.
This is useful for obtaining a wall whose ribs make a more stable corner connection with the ribs of another wall, when the walls are installed on site. Indeed, it is possible to manufacture a wall in which each rib has a first end with an end face that is tilted relative to a plane perpendicular to the longitudinal direction of the rib and each rib has a second end having a tilted recess adapted to receive the end face of a corresponding rib of a second prefabricated wooden wall that is arranged at right angle with the first prefabricated wooden wall.
Basically, the present disclosure relates to a construction method of a prefabricated wooden wall, a machine for manufacturing thereof and accessory devices. The wooden wall is composed by the interlocking joining of two vertical load-bearing planking boards, which are spaced apart and joined by suitably shaped ribs, to achieve a strong structure having a cavity that can be used for inserting insulating material and as a technical compartment.
The method allows to use sawn timber without the need for planing; the assembling is done without glue, with the consequent ecological advantages and cost savings.
The assembling machine makes use of the ribs as a support to the manufacturing and operates by inserting and pushing the planks into the interlocking joints of the ribs themselves. The so-obtained walls can be used directly or with the addition of internal and / or external clothing.
Further advantages, characteristic features and the modes of use of the subject of the present disclosure will become clear from the following detailed description of preferred embodiments thereof, provided by way of example and not for limitative purposes.
It is clear, however, that each embodiment of the subject of the present disclosure may have one or more of the advantages listed above; in any case it is not required for each embodiment to have simultaneously all the advantages listed.
Brief description of figures
Reference shall be made to the figures in the accompanying drawings, in which:
- Figure 1 shows an axonometric cutaway view of a wall according to the present disclosure;
- Figure 2 shows an axonometric view of a plank that belongs to the wall of Figure 1 ;
- Figure 3 shows an axonometric cutaway view of a variant embodiment of a wall according to the present disclosure;
- Figures 4A and 4B show axonometric views of components that belong to the wall of Figure 3;
- Figures 5 to 8 show sectional and axonometric views of an interlocking system according to the present disclosure and of the components thereof;
- Figures 9A to 9D show sectional views of the interlocking system for variant embodiments of a wall according to the present disclosure;
- Figure 10 shows an axonometric view of a machine according to the present disclosure;
- Figures 11 , 12 and 13 show details of an anchoring and aligning system of the machine of Figure 10;
- Figures 14 and 15 show details of a limit stop bar of the machine of Figure 10; - Figure 16 shows a pusher of the machine of Figure 10;
- Figure 16A shows a component of the pusher of Figure 16;
- Figures 17 to 19 show steps of an assembling method for a wall according to the present disclosure;
- Figure 20 shows a corner connection between two walls according to the present disclosure;
- Figures 21 A and 21 B show details of a connecting device of a wall according to the present disclosure; - Figures 22 and 23 show a detail of a variant embodiment of the anchoring and aligning system of the machine of Figure 10, with a rib that is shown released and anchored, respectively.
- Figures 24 to 24A show an axonometric view and end details of a rib to be used with the anchoring and aligning system of Figure 22;
- Figure 25 shows a corner connection between two ribs of Figure 24;
- Figure 26 shows a corner connection between two walls including ribs of Figure 24;
- Figure 27 and 27A show an axonometric view and a details of two ribs that are connected to each other in an aligned condition.
Detailed description of embodiments
Product to be manufactured.
The purpose is to compose a prefabricated wall 1 with two planking boards 2 of vertical planks 3. The planking boards 2 are joined and spaced apart from each other by ribs 4, having a length equal to that of the wall, suitably shaped and having tenons 10 with a dovetail profile 5 on the sides. Specifically, two opposite sides of each rib 4 have respective tenons 10 that extend along the entire length of the rib 4; the tenon 10 on one side is intended to engage mortises 1 1 of the planks 3 of a planking board 2, the tenon 10 on the other side is intended to engage mortises 1 1 of the planks 3 of the second planking board 2. The tenons 10 and the mortises 1 1 have dovetail profiles and compose a dovetail joint system.
The ribs 4, which are spaced apart from each other and are perpendicular to the planks 3 (therefore, they are horizontal in the wall in use), are enclosed between the two planking boards 2, which specifically are parallel. The planking boards 2 and their planks 3 have a load-bearing function for the wall 1.
By means of this technique, it is achieved a structural system that gives better requirements of mechanical strength to the wall, the timber used being equal; a space 6 for insertion of various materials 20 for thermo-acoustic insulation, air tightness and / or fire resistance is arranged. The processing method for the planks allows to directly use sawn timber, avoiding costs and waste from planing.
Elements belonging to the prefabricated wall shown in the figures are:
• a calibration milling 7, to be made on the planking boards 2 (i.e., on the planks 3) simultaneously with a dovetail mortise 11 , to prepare a precise abutment with the ribs 4: the milling 7 calibrates the planks 3 in the points of contact with the ribs 4. In addition, the milling 7 allows the use of non-planed wooden planks 3. In other words, the calibration milling 7 is made on a surface 70 of the plank 3 that is intended to face the other planking board; the calibration milling 7 is recessed in relation to the remaining surface 70. Since the contact between the rib 4 and the surface of the plank 3 is confined to the calibration milling 7, the remaining surface 70 can be non-planed or with an irregular surface, without this having any effect on the dovetail joint system;
· a clearance 9, left between tenon 10 and mortise 1 1 by virtue of a less deep tenon, to solve the problem of inaccuracies due to manufacturing tolerances and to the behaviour of the wood, which is subject to dimensional modifications resulting from humidity changes. In other words, there is non-contact point 9 between planking board and ribs 4; the non-contact point 9 is determined by a smaller depth of the tenon 10 on the rib in comparison with the depth of the corresponding mortise 11 on the planking board. The precise contact between the planking board 2 and the ribs 4 only at two angles 8 allows a reliable, stable and well-defined constraint. Moreover, there is less friction during the assembling of the planks 3 with the ribs 4 when they are inserted;
· shaped ribs 12 with grooves 13, which are useful for positioning and / or laying insulating materials 19 and / or various materials 20 and / or other materials and for leaving empty cavities 14 inside the two planking boards 2.
• shaped ribs 15, 16 as horizontal closing element of the wall 1 , with the possibility of putting technical compartments in them. In other words, the joining elements 15, 16 of the two vertical load-bearing planking boards 2 have dovetail joints and a profile adapted to close a respective horizontal side of the wall 1.
Figures 1 to 4B show the elements of exemplary walls denoted by reference number 1 : planking boards 2, a single milled plank 3, ribs of various types 4, 12, 15, tenons 10 with dovetail 5, cavity 6, calibration milling 7.
Figures 5 to 8 show sectional details and highlight the points of contact 8 between tenon 10 and mortises 1 1 and the clearance 9 that results from the smaller depth of the tenon 10 in comparison with the mortise 1 1. The calibration milling on the planks is highlighted as well and is denoted by reference number 7; the trace of such a milling 7 will not be uniform if it is made on rough planks. The axonometric-view magnification shows the dovetail joint in details. Figures 9A to 9D show some types of ribs 4, 12 for various compositions and stratifications of accessory materials 19, 20, in addition to horizontal closing ribs 15, 16 for the wall 1 , usable both at the bottom and at the top.
In the ribs 12, 15, 16 there may be longitudinal grooves 13 and / or abutments to position and / or lay various types of stratification of insulating materials and / or other materials and / or to leave empty cavities inside the two planking boards.
Firstly, it is pointed out that the use of vertically-arranged planks 3 does not entail problems of deformation in that direction, as it happens in the systems with horizontal load-bearing elements instead.
Secondly, the wall 1 has cheaper costs for materials and better thermal performances than a multiple-planking system, the overall thickness being equal. As a third aspect it is pointed out that, differently from the frame-type or cross-lam systems, the load-bearing element is not at the centre of the wall, but at the sides.
As a matter of fact, the load-bearing function is performed by the planking boards 2.
This entails a larger supporting base, to the advantage of the intrinsic stability, while the joining ribs 4, which serve as stiffening brackets, make the wall 1 a structural system, improving the resistance to static and dynamic stresses.
A fourth aspect is the possibility to compose various stratifications inside the structure, resulting in a broad versatility of performances of the physical features.
A final important aspect is the perception of toughness that the wall shows from both a visual and a tactile point of view.
Assembling technique.
The ribs 4, 12, 15, 16 and the planks 3 required for construction of the wall 1 are prepared in advance.
A machine 90, that is shown in a preferred (but not sole) embodiment in Figures 10 to 19, is used for composing the wall. The machine 90 includes a base with runways 21 and a fixed head 22, two longitudinal side members 23 with supports at the ends, an adjustable support 24 anchored to the head 22, a device 25 for connecting / anchoring the ribs, an adjustable system of alignment 26 and centring 27 of the dovetail joints, a pushing system 28 with a stroke over the entire length of the base and provided with appendages 29 for the insertion of the lower planking and with a height-adjustable crosspiece 30 for the insertion of the upper planking, a limit stop bar 31 with a device 32 of locking to the ribs, provided with an adjuster 33 for limit stop of the upper planking.
The ribs are made firmly joined to the base by means of such devices, while the pusher 28, moving on the base itself, can exert the force required to insert one or more planks at a time into the joints as far as the limit stops, which, blocked by a coupling 32 to the ribs, correctly position the first plank of both the lower planking and the upper planking.
In other words, an exemplary embodiment of a machine for assembling the walls comprises a base with runways or sliding guides 21 and with a head 22 firmly joined to the base, at an end of the base itself. Two side supports or longitudinal members 23 with whole length, raised from the ground and supported at their ends, are at the sides of the base. An adjustable system for anchoring the ribs to the fixed head is attached to the head 22: this is a height-adjustable support on which the adjustable anchoring devices for the ribs and a system of alignment 26 and centring 27 of the dovetail joints, which allow the initial insertion of the planks 3, are located. Specifically, the alignment and centring system includes wedge-shaped guides 27 that facilitate the multiple insertion of the mortises into the respective tenons.
The pusher 28 (or longitudinal pushing device) slides on the base; by means of an adjustable device 29, the pusher 28 positions the planks of the lower planking board as far as the limit stops 31 , which have an adjustable raised support. The pusher 28 slides along the runways or sliding guides 21.
The pusher 28 has a reciprocating movement and, in each stroke towards the limit stop 31 , pushes one or more planks to the limit stop or to the planks already positioned in the previous stroke.
In the present disclosure, reference is made to a lower planking board and to an upper planking board: it should be understood that the terms "lower" and "upper" here refer to the position of the wall on the machine during the assembling. These planking boards will be vertical when the wall is completed and installed on site. The sequence of operations for the composition of the wall is preferably, but not exclusively, as follows.
The ribs of the various types 4, 12, 15, 16, which have the length of the wall to be obtained, are secured to the anchorages 26 with a first end 17 thereof and rest with the other end 18 on the limit stop bar 31 , which in turn rests on the longitudinal members 23. Therefore, the ribs of the wall are constrained with a first end 17 thereof to the fixed part of the machine 90, while the second end 18 of the ribs is supported by a support 31 resting on the longitudinal members 23. The support / limit stop 31 with the coupling 32 is a device serving as a support for an end of the ribs and as a limit stop for the insertion of the planks.
The ribs 4, 12, 15, 16 are used to set the limit stop 31 of the positioning of the planks 3; in fact, the limit stop 31 is displaceable and adjustable according to the length of the ribs.
The ribs are provided with connecting devices 25, 25a, 25b, 25c having the function of constraining and positioning the ribs (therefore, the wall being constructed) to the anchorages 26; the same devices 25, 25a, 25b, 25c have the second function of securing the obtained walls to each other, once installed on site.
In other words, the ribs act as support and adjuster for the composition of the walls by means of the connecting devices 25 that will serve to secure them together when installed on site.
One or more planks 3, previously milled, are positioned on the longitudinal members 23, onto the wedge-shaped sledges 27, and are advanced by the pusher 28 towards the opposite end of the ribs, where the limit stop bar 31 stops them in the desired position. The appendages 29, firmly joined with the pusher 28, prevent the planks from vertically escaping because of the eccentric force applied.
The pusher 28 is brought back and the cycle of insertion of the planks 3 of the first planking board is repeated until the first planking board is completed. In other words, the pusher 28 positions one or more lower-planking-board planks at a time into the dovetail joint of the ribs (i.e., into the lower tenons), up to sequentially compose a first planking board 2 of the wall 1.
At this point, a completed planking rests on the longitudinal members 23 and has the ribs inserted.
Figure 17 shows the machine 90 with the ribs 4 of the wall that are secured with one end 17 thereof to the anchoring systems 24 to the head and with the second end 18 resting on the limit stop bar 31 , to which it is locked by the device 32; the pusher 28 is pushing two planks 3, resting on the longitudinal members 23, towards the limit stop 31. The appendages 29 prevent any lifting of the plank due to the eccentric force applied by the pusher.
The next step is to lay the stratification of materials chosen for isolation, insulation, air tightness, fire resistance, thermal inertia and so on, onto the planking and between the ribs. Figure 18 shows the wall with the completely-made lower planking board and with the insulation panels 20 during manual positioning.
After this, the adjusters and the wedge-shaped sledges 27 are adjusted for the second planking board, the appendages 29 are replaced by the crosspiece 30 of the pusher (adjusted at the suitable height), a limit stop 33 for the upper planking is adjusted.
The planks 3 are positioned at the mouth of the wedge-shaped sledges 27 and the sequential composition of the second planking board is carried out. The pusher 28 positions one or more upper-planking-board planks at a time into the dovetail joint of the ribs (i.e., into the upper tenons), going through the alignment devices, up to sequentially compose the second planking board 2 of the wall 1.
Figure 19 shows the pusher 28 that is positioning two planks 3 of the upper planking board by means of the crosspiece 30; the upper planking board is partly composed from the limit stops 33. The ribs 4 of the whole length of the wall are shown; the ribs will be cut in correspondence of the hole for a door in the completed wall, except for the bottom rib 15 that can be cut in the installed wall, thus enjoying a greater toughness during transport and assembly.
In fact, if there are holes for doors or windows, the planks can be cut to measure and pushed as a group, but the ribs 4 are required to be intact; the ribs will be cut when the wall is completed. In the case of holes for doors, the bottom rib 15 (which will be the lower rib in the wall installed on site) can be left intact until the installation of the wall on site; the bottom rib will be cut later.
It should be noted that, throughout the manufacturing process, the ribs 4, 12, 15, 16 are used as a support for the assembling of the wall itself in the machine 90.
The so-obtained wall can be used directly or it can be clothed both inside and outside. The planking boards can be rough or planed or prepared with male / female interlocking joints or with a connecting core.
Figure 20 shows the right angle between two walls 1 connected by the connecting devices 25, which are the same used for anchoring the ribs to the machine 90.
In a variant embodiment of the machine 90, the device for alignment 26 and initial insertion 27 has abutment surfaces 270 for the first ends 17 of the ribs, wherein these abutment surfaces 270 are at an oblique angle, i.e. they have a non- orthogonal tilt with respect to the insertion direction, i.e. with respect to the longitudinal direction of the wedge-shaped guides 27 and to the longitudinal direction 400 of the ribs 4, 12, 15, 16. Specifically, each wedge-shaped guide 27 has a tilted flat face that is an abutment surface 270 against which an end face 40 of the respective rib abuts.
In particular, each abutment surface 270 forms an angle A ranging between 5 degrees and 10 degrees with respect to a plane perpendicular to said insertion direction or longitudinal direction 400 (Figure 22).
This allows to receive in a fitting manner and to firmly constrain ribs having the first end 17 that is cut with the same tilt: in other words, the rib 4 has an end face 40 that, instead of being perpendicular to the longitudinal direction 400, is tilted with an angle A with respect to perpendicular. Therefore, at the first end 27, a first tenon 10 is longer than the second tenon 10.
When the rib 4 is anchored to the anchoring system 24 through the connecting device 25, the end face 40 is in contact with the whole abutment surface 270 and then a stable positioning of the rib is obtained. This can be further improved by providing protrusions 260 that protrude from the alignment device 26 towards the sides of the rib 4: when the rib 4 is in position, its sides are in contact with the protrusions 260 that prevent unwanted movements (for example: side movements, rotations and inclinations) of the rib 4 with respect to the anchoring system 24.
With this variant embodiment, it is obtained a wall 1 in which the first ends 17 of the ribs have a tilted end face 40. The second ends 18 of the ribs are processed to make a tilted recess 45 or tilted seat having the same tilt A (Figures 24, 24A). When two walls 1 are joined to each other to make a right angle, the tilted end faces 40 of the ribs of the first wall go into the recesses 45 of the ribs of the second wall (Figures 25 and 26), to obtain a corner connection that is stronger thanks to the contrast between the tilted surfaces, wood against wood, and to a step 46 of the recess 45 against which the other rib abuts.
As shown in Figure 27, the connecting device 25 can also be used to join together two ribs in an aligned position instead of forming a corner.
The subject of the present disclosure has been described hitherto with reference to preferred embodiments thereof. It is to be understood that other embodiments relating to the same inventive idea may exist, all falling within the scope of protection of the claims which are provided hereinbelow.

Claims

A machine (90) for manufacturing a prefabricated wooden wall (1), the wall (1) to be manufactured being composed by two planking boards (2) of vertical planks (3) and by horizontal ribs (4, 12, 15, 16), wherein the two planking boards (2) are spaced apart and connected to each other by the ribs (4, 12, 15, 16) through a dovetail joint system, the ribs (4, 12, 15, 16) being provided with dovetail tenons (10) and the planks (3) of the planking boards (2) being provided with corresponding dovetail mortises (11) to receive respective dovetail tenons (10) of the ribs (4, 12, 15, 16),
wherein the machine (90) comprises:
- a base with runways (21), equipped with a fixed head (22);
- two longitudinal members or side supports (23), which extend with whole length at sides of the base;
- an adjustable anchoring system (24) for anchoring the ribs (4, 12, 15, 16) to the fixed head (22);
- a longitudinal pushing device (28), which is slidable along the runways (21);
- a device for alignment (26) and initial insertion (27) of the planks (3) of the planking board (2);
- an adjustable support, which is a limit stop bar (31),
wherein the machine (90) is configured to receive and lock the ribs (4, 12, 15, 16) between the anchoring system (24) and the limit stop bar (31),
wherein the device for alignment (26) and initial insertion (27) is configured to guide the initial insertion of the planks (3) onto first ends (17) of the ribs (4, 12, 15, 16), the dovetail mortises (11) of a plank (3) receiving corresponding dovetail tenons (10) of the ribs (4, 12, 15, 16),
and wherein the longitudinal pushing device (28) is configured to advance one or more planks (3) along the ribs (4, 12, 15, 16) towards the limit stop bar (31). The machine (90) according to claim 1 , wherein the adjustable support or limit stop bar (31) rests on the longitudinal members (23) and is adapted to support second ends (18) of the ribs (4, 12, 15, 16), the adjustable support (31) serving as a rest for the second ends (18) of the ribs (4, 12, 15, 16) and as a limit stop for the insertion of the planks (3) onto the ribs (4, 12, 15, 16).
The machine (90) according to claim 1 or 2, wherein the position of the adjustable support or limit stop bar (31) can be set and adjusted according to the length of the ribs (4, 12, 15, 16).
The machine (90) according to any one of claims 1 to 3, wherein the adjustable support (31) comprises a device (32) for locking the ribs (4, 12, 15, 16).
5. The machine (90) according to any one of claims 1 to 4, wherein the longitudinal members (23) are configured to provide a rest to the planks (3) during the making of a first planking board or lower planking board (2).
6. The machine (90) according to any one of claims 1 to 5, wherein the device for alignment (26) and initial insertion (27) comprises wedge-shaped guides (27) that facilitate the multiple insertion of the mortises (11) of a plank (3) into the corresponding tenons (10) of the ribs (4, 12, 15, 16).
7. The machine (90) according to claim 6, wherein the device for alignment (26) and initial insertion (27) comprises lower wedge-shaped guides (27) and upper wedge-shaped guides (27), the lower wedge-shaped guides (27) being configured to guide the initial insertion of the planks (3) of a first planking board or lower planking board (2), the upper wedge-shaped guides (27) being configured to guide the initial insertion of the planks (3) of a second planking board or upper planking board (2).
8. The machine (90) according to any one of claims 1 to 7, wherein the anchoring system (24) is height adjustable.
9. The machine (90) according to any one of claims 1 to 8, wherein the longitudinal pushing device (28) is configured to sequentially advance one or more planks (3) of a first planking board or lower planking board (3) and one or more planks (3) of a second planking board or upper planking board (3).
10. The machine (90) according to any one of claims 1 to 9, wherein the longitudinal pushing device (28) comprises appendages (29) adapted to prevent the planks (3) from vertically escaping because of the eccentric force applied.
1 1. The machine (90) according to any one of claims 1 to 10, wherein the longitudinal pushing device (28) comprises a height-adjustable crosspiece (30) adapted to push the planks (3).
12. The machine (90) according to any one of claims 1 to 11 , wherein the anchoring system (24) comprises abutment surfaces (270) for receiving end faces (40) of the ribs (4, 12, 15, 16), said abutment surfaces (270) having a tilt that is non- orthogonal with respect to an insertion direction or longitudinal direction (400) of the ribs (4, 12, 15, 16), more particularly said tilt ranging between 5 degrees and 10 degrees with respect to a plane perpendicular to the insertion direction or longitudinal direction (400).
13. A method for manufacturing a prefabricated wooden wall (1), the wall (1) to be manufactured being composed by two planking boards (2) of vertical planks (3) and by horizontal ribs (4, 12, 15, 16), wherein the two planking boards (2) are spaced apart and connected to each other by the ribs (4, 12, 15, 16) through a dovetail joint system, the ribs (4, 12, 15, 16) being provided with dovetail tenons (10) and the planks (3) of the planking boards (2) being provided with corresponding dovetail mortises (1 1) to receive respective dovetail tenons (10) of the ribs (4, 12, 15, 16),
wherein the method comprises the steps of:
- providing a plurality of said ribs (4, 12, 15, 16);
- providing a plurality of said planks (3);
- positioning and anchoring the ribs (4, 12, 15, 16) to an assembling machine (90);
- positioning one or more planks (3) at a time into a lower dovetail joint (10) of the ribs (4, 12, 15, 16), up to sequentially compose a first planking board or lower planking board (2) of the wall (1);
- positioning one or more planks (3) at a time into an upper dovetail joint (10) of the ribs (4, 12, 15, 16), up to sequentially compose a second planking board or upper planking board (2) of the wall (1).
14. The method according to claim 13, wherein:
- said assembling machine is a machine (90) according to any one of claims 1 to 12;
- the ribs (4, 12, 15, 16) are positioned and anchored between the anchoring system (24) and the limit stop bar (31), the first ends (17) of the ribs (4, 12, 15,
16) being constrained to the anchoring system (24) and the second ends (18) of the ribs (4, 12, 15, 16) being resting on the limit stop bar (31);
- the planks (3) are positioned into the lower dovetail joint (10) of the ribs (4, 12, 15, 16) by means of the longitudinal pushing device (28);
- the planks (3) are positioned into the upper dovetail joint (10) of the ribs (4, 12, 15, 16) by means of the longitudinal pushing device (28).
15. The method according to claim 14, wherein the first ends (17) of the ribs (4, 12, 15, 16) are constrained to the anchoring system (24) through connecting devices (25, 25a, 25b, 25c) that are the same connecting devices that are used to secure the prefabricated wooden wall (1) to another prefabricated wooden wall (1), when the prefabricated walls (1) are installed on site.
16. The method according to any one of claims 13 to 15, wherein the ribs (4, 12, 15, 16) serve as a support for assembling the wall (1) in said assembling machine (90).
17. The method according to any one of claims 13 to 16, wherein, after composing the first planking board or lower planking board and before composing the second planking board or upper planking board, materials (20) for thermo- acoustic insulation and / or for air tightness and / or for fire resistance are laid between the ribs (4, 12, 15, 16), said materials (20) being intended to stay in the space (6) between the two planking boards (2).
18. The method according to any one of claims 13 to 17, wherein the step of providing a plurality of said planks (3) comprises a sub-step of making calibration millings (7) on said planks (3), the calibration millings (7) being adapted to calibrate the planks (3) at points (8) that are intended for contacting the respective ribs (4, 12, 15, 16), each calibration milling (7) defining an abutment with a respective rib (4, 12, 15, 16),
and wherein the dovetail mortises (11) are made with such a depth that the dovetail tenon (5, 10) has a smaller depth than the corresponding dovetail mortise (1 1), so as to leave a clearance (9) between the tenon (5, 10) and the mortise (1 1), the clearance determining a non-contact point between the plank (3) and the rib (4, 12, 15, 16).
19. The method according to claim 18, wherein said planks (3) are non-planed wooden planks, each calibration milling (7) being made on a non-planed surface (70) of the plank (3) and being recessed in relation to the remaining non-planed surface (70) of the plank (3).
20. The method according to claim 18 or 19, wherein the sub-step of making calibration millings (7) is carried out simultaneously with a step of making the dovetail mortises (1 1).
21. A prefabricated wooden wall (1) composed by two planking boards (2) of planks (3) and by ribs (4, 12, 15, 16), the two planking boards (2) being spaced apart and connected to each other by the ribs (4, 12, 15, 16) through a dovetail joint system, the ribs (4, 12, 15, 16) being provided with dovetail tenons (5, 10) and the planks (3) of the planking boards (2) being provided with corresponding dovetail mortises (11) to receive respective dovetail tenons (10) of the ribs (4, 12, 15, 16),
wherein each planking boards (2) is made of vertically-arranged planks (3) and said ribs (4, 12, 15, 16) are horizontally arranged.
22. The prefabricated wooden wall (1) according to claim 21 , wherein said ribs (4, 12, 15, 16) comprise connecting devices (25, 25a, 25b, 25c) for securing the prefabricated wooden wall (1) to another prefabricated wooden wall (1), when the prefabricated walls (1) are installed on site, said connecting devices (25, 25a, 25b, 25c) being the same connecting devices that, during manufacturing of the wall (1), serve to constrain the ribs (4, 12, 15, 16) to an anchoring system (24) of an assembling machine (90).
23. The prefabricated wooden wall (1) according to claim 21 or 22, wherein each rib (4, 12, 15, 16) has a first end (17) having an end face (40) that is tilted with respect to a plane perpendicular to a longitudinal direction (400) of the rib (4, 12, 15, 16), and a second end (18) having a tilted recess (45) adapted to receive the end face (40) of a corresponding rib of a second prefabricated wooden wall that is arranged at right angle with the prefabricated wooden wall (1), more particularly the tilt of said end face (40) ranging between 5 degrees and 10 degrees with respect to a plane perpendicular to the longitudinal direction (400).
24. The prefabricated wooden wall (1) according to any one of claims 21 to 23, wherein the dovetail joint system comprises a calibration milling (7) that calibrates the planks (3) at points (8) of contact with the ribs (4, 12, 15, 16), the calibration milling (7) defining an abutment with a respective rib (4, 12, 15, 16),
and wherein the dovetail tenon (5, 10) has a smaller depth than the corresponding dovetail mortise (11), so as to leave a clearance (9) between the tenon (5, 10) and the mortise (11), the clearance determining a non-contact point between the planking board (2) and the rib (4, 12, 15, 16).
25. The prefabricated wooden wall (1) according to claim 24, wherein said abutment is defined by the calibration milling (7) on the surface (70) of the planking board (2) around a respective dovetail mortise (1 1) and is recessed in relation to the remaining surface (70) of the planking board (2).
26. The prefabricated wooden wall (1) according to claim 25, wherein said planks (3) are non-planed wooden planks.
27. The prefabricated wooden wall (1) according to any one of claims 21 to 26, comprising materials (20) for thermo-acoustic insulation and / or for air tightness and / or for fire resistance, said materials (20) being in the space (6) between the two planking boards (2).
28. The prefabricated wooden wall (1) according to any one of claims 21 to 27, wherein at least some (12, 15, 16) of said ribs comprise longitudinal grooves (13) and / or abutments for positioning or laying insulating materials (19) and / or other materials and /or for leaving empty cavities (14) in the space (6) inside the two planking boards (2).
29. The prefabricated wooden wall (1) according to any one of claims 21 to 28, wherein at least one (15, 16) of said ribs is a horizontal closing element or profile adapted to close a respective horizontal side of the prefabricated wooden wall (1), more particularly the prefabricated wooden wall (1) comprises a top horizontal closing rib (15, 16) and a bottom horizontal closing rib (15, 16).
EP14714342.4A 2013-02-13 2014-02-13 Machine and method for manufacturing a prefabricated wall and a prefabricated wall Withdrawn EP2956595A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000001A ITTN20130001A1 (en) 2013-02-13 2013-02-13 PROCEDURE FOR THE REALIZATION OF PREFABRICATED WOOD WALLS COMPOSED BY TWO ASSETS IN VERTICAL TABLES, DISTANCED AND CONNECTED BETWEEN THEM BY HORIZONTAL RIBS WITH SWINGED TAIL.
PCT/IB2014/058975 WO2014125435A2 (en) 2013-02-13 2014-02-13 Machine and method for manufacturing a prefabricated wall and a prefabricated wall

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CN104358415B (en) * 2014-11-17 2016-02-24 石家庄铁道大学 Concrete prefabricated element can be recombinated portable production system and production method thereof
FR3057883B1 (en) * 2016-10-26 2020-11-06 Herve Bertrand MODULAR STRUCTURAL PANEL AND ASSEMBLY CONTAINING SUCH PANELS FOR THE CONSTRUCTION OF A BUILDING

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US2754862A (en) * 1955-11-07 1956-07-17 Jr John M Kemp Method of and apparatus for prefabricating wall structures
DE19959827B4 (en) * 1999-12-10 2006-12-14 Horst Himmler Wall element, in particular for wooden houses and method for its production
ITBZ20050031A1 (en) 2005-06-17 2006-12-18 Reinverbund S R L WALL ELEMENT FOR BUILDING AND COMPOSITE WOOD LAYER PANEL
WO2007068267A1 (en) * 2005-12-13 2007-06-21 Ludwig Junker Sägewerk und Holzhandel GmbH Wooden building element for constructing the walls of a building
FR2930959B1 (en) * 2008-05-06 2013-01-25 Guidel UNIVERSAL COMPLETE ELEMENT IN SOLID WOOD
DE102010008684A1 (en) * 2010-02-19 2011-08-25 Junker Holding GmbH, 77787 Method for manufacturing of articles from wood, particularly structural elements, such as boards or structural panels for construction and configuration of walls on buildings, involves manufacturing section from wood by formative processing

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