EP3119947B1 - Method for producing a slab of insulating material for use in buildings - Google Patents
Method for producing a slab of insulating material for use in buildings Download PDFInfo
- Publication number
- EP3119947B1 EP3119947B1 EP15718604.0A EP15718604A EP3119947B1 EP 3119947 B1 EP3119947 B1 EP 3119947B1 EP 15718604 A EP15718604 A EP 15718604A EP 3119947 B1 EP3119947 B1 EP 3119947B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- slab
- slabs
- cutting device
- insulating material
- panel
- 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.)
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- 239000011810 insulating material Substances 0.000 title claims description 16
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 238000005520 cutting process Methods 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000000463 material Substances 0.000 description 22
- 239000004567 concrete Substances 0.000 description 15
- 239000002023 wood Substances 0.000 description 11
- 239000004795 extruded polystyrene foam Substances 0.000 description 7
- 239000004033 plastic Substances 0.000 description 7
- 238000012545 processing Methods 0.000 description 7
- 239000011449 brick Substances 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 238000005192 partition Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 238000003801 milling Methods 0.000 description 3
- 239000011490 mineral wool Substances 0.000 description 3
- 239000011150 reinforced concrete Substances 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229920002522 Wood fibre Polymers 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- OQCFWECOQNPQCG-UHFFFAOYSA-N 1,3,4,8-tetrahydropyrimido[4,5-c]oxazin-7-one Chemical compound C1CONC2=C1C=NC(=O)N2 OQCFWECOQNPQCG-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000002860 competitive effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 229920006248 expandable polystyrene Polymers 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 239000011491 glass wool Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Images
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
- E04C2/20—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 plastics
- E04C2/205—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 plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
- B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
- B26D1/06—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates
- B26D1/08—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates of the guillotine type
- B26D1/09—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates of the guillotine type with a plurality of cutting members
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
- B26D3/006—Cutting work characterised by the nature of the cut made; Apparatus therefor specially adapted for cutting blocs of plastic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/38—Cutting-out; Stamping-out
- B26F1/44—Cutters therefor; Dies therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F3/00—Severing by means other than cutting; Apparatus therefor
- B26F3/06—Severing by using heat
- B26F3/08—Severing by using heat with heated members
- B26F3/12—Severing by using heat with heated members with heated wires
-
- 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
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/163—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, only the vertical slabs being partially cast in situ
-
- 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
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/24—Safety or protective measures preventing damage to building parts or finishing work during construction
- E04G21/26—Strutting means for wall parts; Supports or the like, e.g. for holding in position prefabricated walls
-
- 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
- E04B2/8623—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers and at least one form leaf being monolithic
- E04B2/8629—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers and at least one form leaf being monolithic with both form leaves and spacers being monolithic
Definitions
- the present invention concerns a method for producing a slab made of insulating material for use in buildings, able to be used in particular to make external and internal walls of buildings, partition walls and retaining walls.
- prefabricated modular systems are currently known for making mixed structures of concrete and alternative material to those in use in conventional building.
- An example of these known systems is described in document EP 0 163 117 A1 and foresees the construction of a wall by putting together a plurality of blocks or "bricks" made of foamed plastic material.
- the assembled blocks form vertical channels that run through the inside of the wall for its entire height and are configured to be filled with concrete jets.
- the latter once set, forms a series of pillars that give the wall the necessary structural strength.
- the authors of the present invention have observed that such a prefabricated system still has some drawbacks.
- US 5 943 775 A discloses a method for producing a slab made of insulating material, comprising the steps of:
- a purpose of the present invention is to avoid the aforementioned drawbacks of the state of the art, and in particular to provide a tailored-module system and a method for making walls, partition walls or other parts of buildings, made of thermally insulating materials that are lighter than concrete or known bricks, which are quicker and simpler to apply with respect to modular systems that are currently known.
- Figures 1-4 and 6 relate to a tailored-module system for making walls, partition walls and other parts of buildings according to a particular embodiment of the invention.
- a tailored-module system comprises one or more slabs 1, each of which comprises a plurality of passing channels 3 that pass from one side of the slab to the other in a direction substantially parallel to the two major faces of the slab itself ( figure 1 ).
- the slab is advantageously made of one or more thermally insulating materials, like for example a foamed polymeric material, wood or wood fibre, rock wool, mineralised wood.
- EPS foamed polystyrene
- XPS extruded polystyrene foam
- the slab is advantageously made of a material having a thermal conductivity, measured according to the standard EN 12667, of 0.3 W/ (mK) or less, more preferably of 0.05 W/ (mK) or less and even more preferably of 0.035 W/(mK) or less.
- the slabs 1 have a height HL, in a direction parallel to that of the passing channels 3, of 0.5 metres or more, more preferably of 1 metre or more and even more preferably of 1.5-2 metres or more, so that a single slab 1 extends over the entire height of the wall that it is to be part of.
- the two smaller faces of the slab 1 onto which the channels 3 open preferably form flat surfaces, so as to be able to be formed also by simply cutting a slab and not necessarily through moulding or complicated milling processing.
- the width WL of the slabs 1 can for example be of 0.3 metres or more, comprised between 0.9-2.4 metres, comprised between 1-1.4 metres, or even equal to 1.2 metres.
- the slabs 1 can form part of a tailored-module system of prefabricated slabs that comprises different slabs the widths of which WL', WL" can be sub-multiples of the width WL of the slab 1.
- the sub-multiple widths of the slabs WL', WL", WL'" , WL can be equal to 5 cm, 10 cm, 15 cm, 0.3 m, 0.45 m, 0.6 m.
- the slabs 1 can have a thickness SL of 0.15 metres or more, of 0.25 metres or more, of 0.30 metres or more, comprised between 0.25-1 metres or else comprised between 0.25-0.5 metres.
- the ratio between the minimum dimension between height HL and width WL, and the thickness SL is of 3 times or more, i.e. it is: Min HL WL / SL ⁇ 3 and more preferably it is of 4 or more or 5 times.
- the passing channels 3 preferably extend rectilinearly and are of shape and size such as to be able to contain jets of concrete and possible iron reinforcement cages, or steel/wood bars or beams with or without the presence of concrete, and thus be able to be used as disposable formwork, as will be described in more detail hereafter.
- each channel 3 preferably has a minimum passing section of 50 square centimetres (cm 2 ) or more, more preferably of 77-80 cm 2 or more and even more preferably of 175-180 cm 2 or more.
- the passing channels are obtained by cutting, milling or perforating a full slab, for example with the hot wire method.
- Such processing also makes the production of small batches of slabs 1 economically advantageous, sufficient to make a single installation or project (like for example the construction of a new building or the restructuring, raising, seismic reinforcement of an old building) and make it possible to adapt the interaxial distance between the channels 3, and therefore between the pillars 13, with substantial freedom and fairly low costs based on the specific requirements of the project itself.
- the hot wire method can be advantageously exploited in the following way: the cut 30, which is used by the hot wire to reach the inner area of the slab in which to cut a channel 3, preferably lies in a plane passing through the axis of the channel 3 and inclined according to a predetermined angle with respect to the major faces of the slab 1 ( figure 2 ).
- the plane can be both perpendicular to the major faces of the slab 1, and oblique, for example for antiseismic structures.
- a portion of the mounting guide 5 projects outside of the slab 1 and preferably forms a resting area 52 that substantially lies in a plane parallel to the major faces of the slab 1.
- an edge 54 of the guide portion that projects outside of the slab 1 bends so as to insert back into the slab 1, for example inside a further slit 34 that also runs longitudinally to the channel 3.
- another portion of the guide 5 reaches the channel 3 and an edge thereof 56 bends (for example in a U) so as to insert into a third slit 32 that extends longitudinally to the channel 3 and, starting from the inner wall thereof, penetrates into the material of the slab 1 without however reaching the outside.
- the couplings with the slits 30, 32 and 34 make it possible to very firmly fix the guide 5 to the slab 1 before casting the concrete in the channels 3, in particular preventing the cross sections of the guide from rotating with respect to the slab.
- the guides 5 are embedded in the concrete of the future pillars 13 that will be cast in the holes 3, or at least rest directly against such pillars 13, and therefore discharging the forces that the guides 5 may be subjected to onto them instead of onto the material of the slab 1.
- couplings are formed, for example of the male/female type with longitudinal ribs 36 that insert into longitudinal throats 38, to couple and constrain an edge of a slab 1 to that of a second slab 1 analogous and adjacent to the first.
- Each slab 1 can be grooved so as to obtain open grooves. Each slab 1 can thus be used to make horizontal structures for floors.
- the grooves are configured to receive the beam made of reinforced concrete of the floor of any width and pitch.
- the slabs 1 are produced with the method and the machine shown in figure 6 .
- Such a machine indicated with overall reference numeral 100, comprises a work table or plane 102 to which a plurality of cutting devices 104 is fixed, like for example cutting dies, blades or punches.
- the work plane 102 can be a simple metallic plane, or a plane with rollers, idle or motorised, which promote the advancing of the semi-finished blocks or panels 106 described in greater detail hereafter.
- Each cutting die 104 is preferably formed from one or more suitably shaped metal sheets.
- the cutting dies 104 that must cut the channels 3 can comprise a tubular portion 108 and a sustaining portion 110, which supports the tubular portion 108 keeping it in a predetermined position with respect to the work plane 102.
- the machine 100 can also comprise other cutting dies 112, 114 arranged to cut the longitudinal ribs 36 or the longitudinal throats 38 that run along the lateral edges of the slabs 1, and possibly trim such edges.
- the machine 100 is advantageously provided with an advancing system, not shown, arranged to advance a semi-finished block or panel 106 of EPS, XPS or other foamed plastic material, along a predetermined direction F.
- the advancing system can for example comprise motorised wheels or rollers, pneumatic cylinders or drive chain systems.
- the machine 100 can be used by heating the cutting dies, knives or punches 104, 112, 114 up to a temperature such as to melt the plastic material of the slabs 1.
- a semi-finished block or panel 106 is rested and slid on top of the work plane 102 according to a predetermined direction F, so that it hits the cutting dies 104, 112, 114 and the latter dig or cut into the block 106, with very fast, cost-effective and flexible machining, the channels 3, the ribs 36, the throats 38 and/or the grooves.
- the sustaining portions 110 cut the slits 30 that extend from a wall of a respective channel 3 up to one of the two major faces of the finished slab 1 and receive the metallic guides 5.
- the position of the cutting dies 104, 112, 114 on the work plane 102 can be changed, in particular in directions parallel to the same work plane 102, thus varying the interaxial distance between the channels 3 that are formed.
- the costs for this processing change are practically negligible and this makes it possible to produce small batches of slabs 1, at very competitive costs, with the most suitable interaxial distance between the channels 3 for a specific project.
- the method according to the present invention thus allows fast processing of the slabs 1 at very low cost.
- the semi-finished block or panel 106 runs in line in the machine 100 and meets the cutting dies, blades or punches 104, heated and preformed, which sublimate the EPS.
- the panel is immobile and it is the standard tool that moves.
- the semi-finished block or panel 106 can have any length.
- the machine 100 can produce even two slabs 1 simultaneously, with all of the channels 3, the ribs 36, the throats 38 and/or the grooves required, and therefore it has greater productivity than pantographs.
- the machine 100 cannot be provided with programming, is simple to use and does not therefore require highly trained workers, or high programming and tuning costs.
- the machine 100 is of small dimensions, so as to be able to be transported on a normal truck and positioned even on the building yard.
- the investment for making a machine 100 is less (roughly 50%) with respect to that necessary for a pantograph and is considerably less (more than ten times less) with respect to what is required to fit out a plant for moulding slabs made of EPS.
- suitable floor guides 7, which can for example be rods or bars with L-shaped cross-section, and the fastening plates 9 to which to anchor the future load-bearing structure made of concrete or reinforced concrete inside the slabs 1 themselves, are fixed.
- the slabs 1, with the relative guides 5 already mounted, are applied referring to the floor guides 7 and plumbed referring for example to the guides 5.
- the slabs 1 were produced with a height HL equal to that of the entire wall to be made, thus making it faster and easier to make the wall and substantially reducing the manual application operations.
- suitable lintel modules 8 are arranged, having the function of structurally connecting the concrete casts of the different pillars 13 to each other or to the cast of a second floor, foundation or base that must be supported by the pillars 13 themselves.
- the reinforcement cages 11 of the future pillars 13, i.e. the steel/wood bars or beams, are inserted from the top into the relative channels 5 and fixed to the fastening plates 9, after which the latter are filled with possible concrete casts, where foreseen.
- a composite wall is obtained, formed from the slabs 1 internally reinforced by a series of pillars 13 having the structural function both of supporting possible overlying structures, and of flexurally reinforcing the wall itself against possible knocking down.
- the pillars 13 can be suitably close together and, by making them through cutting with hot wire, milling or drilling, the channels 3 can be positioned in the slabs 1 with the interaxial distance most suitable for each installation and very low costs.
- the composite wall can be finished by fixing for example panels made of plasterboard, wood or other coatings, or suitably plastered, to the guides 5.
- Figure 5 relates to a slab 1' according to another embodiment not made according to the invention.
- the slab 1' is formed from many different materials: two outer panels 15 and 17 for example made of wood fibre, or hardboard, between which blocks 19, 19', 19" of rock wool are arranged. Between the blocks 19, 19', 19" some passing channels 3' are formed.
- the choice of materials can also be different, being able to make the outer panels 15, 17 for example of mineralised laminated wood, or other materials derived from wood, rock or glass wool or other mineral insulators, and the blocks 19, 19', 19” can for example be made of wood or derivatives thereof, or foamed plastic materials.
- the slabs 1 can be applied with much less manual operations; moreover, thanks to their relatively large size, the slabs 1, 1' can be aligned and plumbed with greater ease and much greater precision; they reduce the number and overall extension of the slits through the layer of insulating material of the wall itself, thus increasing the impermeability thereof to air, humidity, to other atmospheric agents and to noise; they can be transported and moved much more easily on the building site, since the slabs are easier to hold, harness or bind, for example to be lifted with a hoist, with respect to an incoherent mass of insulating blocks in the form of bricks.
- the slabs 1 made of EPS, XPS or other similar light materials eliminate very many problems of worker safety when they are moved on the building site.
- the composite wall described above, in particular if made of EPS, XPS or other foamed plastic materials is much lighter, less expensive and provided with much better thermal and sound insulation with respect to conventional walls made of solid reinforced concrete or of bricks, since on large portions thereof the entire thickness of such a composite wall is substantially occupied by just EPS or another insulating material.
- the slabs 1 are obtained from the cutting of blocks manufactured from EPS, XPS or other similar light and insulating materials. Such a processing procedure makes it possible to make any shape, size and interaxial distance of pillar (even round walls) and any size of panel without the typical constraints of moulding.
- the slabs 1 are not therefore manufactured in series and there is not a limited choice of types of panels, since such slabs 1 are made to size each time, adapting them to the architectural and structural design of the building.
- the cutting process also allows the insertion in the factory of accessories and personalisation, like for example home fittings, counterframes for doors and windows, shutter boxes, guides for rainscreens, plasterboard panels, etc., of any shape and size. It is also possible to make side panels for floors.
- a slab according to the invention can comprise a layer of foamed plastic material, like for example EPS or XPS, on which a panel made of wood or a wood-derived material is glued or in any case coupled.
- foamed plastic material like for example EPS or XPS
- all of the details can be replaced by technically equivalent elements.
- the materials used, as well as the sizes can be whatever according to the technical requirements. It should be understood that an expression of the type "A comprises B, C, D" or "A is formed from B, C, D" also comprises and describes the particular case in which "A consists of B, C, D".
- the examples and lists of possible variants of the present application should be considered to be non-exhaustive lists.
Description
- The present invention concerns a method for producing a slab made of insulating material for use in buildings, able to be used in particular to make external and internal walls of buildings, partition walls and retaining walls.
- In order to make walls or partition walls of buildings that are lighter and capable of providing greater thermal and sound insulation, prefabricated modular systems are currently known for making mixed structures of concrete and alternative material to those in use in conventional building. An example of these known systems is described in document
EP 0 163 117 A1 and foresees the construction of a wall by putting together a plurality of blocks or "bricks" made of foamed plastic material. The assembled blocks form vertical channels that run through the inside of the wall for its entire height and are configured to be filled with concrete jets. The latter, once set, forms a series of pillars that give the wall the necessary structural strength. The authors of the present invention have observed that such a prefabricated system still has some drawbacks. The construction of such a wall requires that a relatively large number of blocks be laid down, and therefore needs a long and expensive manual work step. The numerous separating surfaces between the blocks constitute an equally large number of potential, if not actual, routes for infiltration of external humidity. In order to be able to make their complex shape at acceptable costs, the blocks must be obtained from a mould, making it relatively expensive, for example, to adapt the interaxial distance between the pillars from one installation to another. - Further prefabricated modular systems for making mixed structures of concrete and insulating materials are described, for example, in documents
WO 2011/060118 A2 ,US 5 645 542 A andDE 102 51 286 A1 . Typically, the slabs made of insulating material of known systems are manufactured through direct moulding. Manufacturing through direct moulding, however, imposes some shape and size constraints, not allowing panels of all shapes and sizes to be made. DocumentUS 5 943 775 A discloses a method for producing a polymeric foamed material panel wherein a polymeric foamed material is cut to form the panel. The polymeric foamed material is held on a working machine, whereas the cutting tools of the working machine need to be moved to produce the desired polymeric foamed material panels Specifically,US 5 943 775 A discloses a method for producing a slab made of insulating material, comprising the steps of: - arranging a work plane on a machine;
- arranging at least one cutting device and heating it up to a temperature such as to be able to melt the insulating material;
- obtaining from a semi-finished block or panel made of insulating material one or more of the following elements:
- a passing channel,
- a longitudinal rib,
- a longitudinal groove, or
- a longitudinal throat configured to couple and constrain an edge of a first slab to that of a second slab analogous and adjacent to said first slab.
- A purpose of the present invention is to avoid the aforementioned drawbacks of the state of the art, and in particular to provide a tailored-module system and a method for making walls, partition walls or other parts of buildings, made of thermally insulating materials that are lighter than concrete or known bricks, which are quicker and simpler to apply with respect to modular systems that are currently known.
- Such a purpose is achieved with a method for producing a slab made of insulating material for use in building having the characteristics according to
claim 1. Further characteristics of the invention are the object of the dependent claims. - The advantages that can be obtained with the present invention will become clearer, to the person skilled in the art, from the following detailed description of some particular non-limiting embodiments thereof, illustrated with reference to the following schematic figures.
-
Figures 1 and2 respectively show a first and a second perspective view of a slab, with relative guides, of a tailored-module system made by the method according to the invention; -
figure 3 shows a perspective view of a mounting guide of the slab offigure 1 ; -
figure 4 shows a perspective view of an instance of an example of mounting the tailored-module system offigure 1 ; -
figure 5 shows another slab of a tailored-module system; and -
figure 6 shows a perspective view of a machine for producing the slabs offigure 2 . -
Figures 1-4 and6 relate to a tailored-module system for making walls, partition walls and other parts of buildings according to a particular embodiment of the invention. Such a tailored-module system comprises one ormore slabs 1, each of which comprises a plurality ofpassing channels 3 that pass from one side of the slab to the other in a direction substantially parallel to the two major faces of the slab itself (figure 1 ). The slab is advantageously made of one or more thermally insulating materials, like for example a foamed polymeric material, wood or wood fibre, rock wool, mineralised wood. - Particularly advantageous materials for properties of thermal and acoustic insulation, mechanical strength and suitability for containing jets of concrete, i.e. steel/wood bars or beams with or without the presence of concrete, which will go to form the pillars 13, lightness and ease of processing and handling also on the worksite are foamed polystyrene (EPS) or extruded polystyrene foam (XPS).
- Preferably, the slab is advantageously made of a material having a thermal conductivity, measured according to the standard EN 12667, of 0.3 W/ (mK) or less, more preferably of 0.05 W/ (mK) or less and even more preferably of 0.035 W/(mK) or less.
- Advantageously, the
slabs 1 have a height HL, in a direction parallel to that of thepassing channels 3, of 0.5 metres or more, more preferably of 1 metre or more and even more preferably of 1.5-2 metres or more, so that asingle slab 1 extends over the entire height of the wall that it is to be part of. For this purpose, the two smaller faces of theslab 1 onto which thechannels 3 open preferably form flat surfaces, so as to be able to be formed also by simply cutting a slab and not necessarily through moulding or complicated milling processing. - As an example, the width WL of the
slabs 1 can for example be of 0.3 metres or more, comprised between 0.9-2.4 metres, comprised between 1-1.4 metres, or even equal to 1.2 metres. - The
slabs 1 can form part of a tailored-module system of prefabricated slabs that comprises different slabs the widths of which WL', WL" can be sub-multiples of the width WL of theslab 1. For example, the width can be WL' = WL/2; WL" = WL/4; WL'" = WL/2, 66667. For example, if the width is WL = 1.2 m, the sub-multiple widths of the slabs WL', WL", WL'" , WL can be equal to 5 cm, 10 cm, 15 cm, 0.3 m, 0.45 m, 0.6 m. - Again as an example, the
slabs 1 can have a thickness SL of 0.15 metres or more, of 0.25 metres or more, of 0.30 metres or more, comprised between 0.25-1 metres or else comprised between 0.25-0.5 metres. -
- The
passing channels 3 preferably extend rectilinearly and are of shape and size such as to be able to contain jets of concrete and possible iron reinforcement cages, or steel/wood bars or beams with or without the presence of concrete, and thus be able to be used as disposable formwork, as will be described in more detail hereafter. For this purpose eachchannel 3 preferably has a minimum passing section of 50 square centimetres (cm2) or more, more preferably of 77-80 cm2 or more and even more preferably of 175-180 cm2 or more. - Preferably the passing channels are obtained by cutting, milling or perforating a full slab, for example with the hot wire method. Such processing also makes the production of small batches of
slabs 1 economically advantageous, sufficient to make a single installation or project (like for example the construction of a new building or the restructuring, raising, seismic reinforcement of an old building) and make it possible to adapt the interaxial distance between thechannels 3, and therefore between the pillars 13, with substantial freedom and fairly low costs based on the specific requirements of the project itself. - The hot wire method can be advantageously exploited in the following way: the
cut 30, which is used by the hot wire to reach the inner area of the slab in which to cut achannel 3, preferably lies in a plane passing through the axis of thechannel 3 and inclined according to a predetermined angle with respect to the major faces of the slab 1 (figure 2 ). The plane can be both perpendicular to the major faces of theslab 1, and oblique, for example for antiseismic structures. - A
metallic guide 5, in particular thecentral portion 50 of its cross section, is inserted into thecut 30. A portion of themounting guide 5 projects outside of theslab 1 and preferably forms aresting area 52 that substantially lies in a plane parallel to the major faces of theslab 1. Possibly, anedge 54 of the guide portion that projects outside of theslab 1 bends so as to insert back into theslab 1, for example inside afurther slit 34 that also runs longitudinally to thechannel 3. Preferably another portion of theguide 5 reaches thechannel 3 and an edge thereof 56 bends (for example in a U) so as to insert into athird slit 32 that extends longitudinally to thechannel 3 and, starting from the inner wall thereof, penetrates into the material of theslab 1 without however reaching the outside. The couplings with theslits guide 5 to theslab 1 before casting the concrete in thechannels 3, in particular preventing the cross sections of the guide from rotating with respect to the slab. - Thanks to such an arrangement, the
guides 5 are embedded in the concrete of the future pillars 13 that will be cast in theholes 3, or at least rest directly against such pillars 13, and therefore discharging the forces that theguides 5 may be subjected to onto them instead of onto the material of theslab 1. - Preferably, on the smaller faces of the
slab 1 parallel to thechannels 3 couplings are formed, for example of the male/female type withlongitudinal ribs 36 that insert intolongitudinal throats 38, to couple and constrain an edge of aslab 1 to that of asecond slab 1 analogous and adjacent to the first. - Each
slab 1 can be grooved so as to obtain open grooves. Eachslab 1 can thus be used to make horizontal structures for floors. The grooves are configured to receive the beam made of reinforced concrete of the floor of any width and pitch. - If in structural terms the load-bearing capacity of a single pillar 13 were not sufficient, it is possible to lengthen the section of such a pillar 13 creating dividing or load-bearing walls in the
slab 1. In order to counteract the thrust of the concrete being cast, longitudinal grooves are made with respect to the development plane of theslab 1 and plastic connectors are inserted transversally. Such dividing or load-bearing walls can have any length and thickness with a maximum of 50 cm. - The
slabs 1 are produced with the method and the machine shown infigure 6 . Such a machine, indicated withoverall reference numeral 100, comprises a work table orplane 102 to which a plurality ofcutting devices 104 is fixed, like for example cutting dies, blades or punches. Thework plane 102 can be a simple metallic plane, or a plane with rollers, idle or motorised, which promote the advancing of the semi-finished blocks orpanels 106 described in greater detail hereafter. - Each cutting die 104 is preferably formed from one or more suitably shaped metal sheets. The cutting dies 104 that must cut the
channels 3 can comprise atubular portion 108 and a sustainingportion 110, which supports thetubular portion 108 keeping it in a predetermined position with respect to thework plane 102. Themachine 100 can also comprise other cutting dies 112, 114 arranged to cut thelongitudinal ribs 36 or thelongitudinal throats 38 that run along the lateral edges of theslabs 1, and possibly trim such edges. - The
machine 100 is advantageously provided with an advancing system, not shown, arranged to advance a semi-finished block orpanel 106 of EPS, XPS or other foamed plastic material, along a predetermined direction F. The advancing system can for example comprise motorised wheels or rollers, pneumatic cylinders or drive chain systems. - The
machine 100 can be used by heating the cutting dies, knives or punches 104, 112, 114 up to a temperature such as to melt the plastic material of theslabs 1. A semi-finished block orpanel 106 is rested and slid on top of thework plane 102 according to a predetermined direction F, so that it hits the cutting dies 104, 112, 114 and the latter dig or cut into theblock 106, with very fast, cost-effective and flexible machining, thechannels 3, theribs 36, thethroats 38 and/or the grooves. Advantageously, the sustainingportions 110 cut theslits 30 that extend from a wall of arespective channel 3 up to one of the two major faces of thefinished slab 1 and receive the metallic guides 5. - Advantageously, the position of the cutting dies 104, 112, 114 on the
work plane 102 can be changed, in particular in directions parallel to thesame work plane 102, thus varying the interaxial distance between thechannels 3 that are formed. The costs for this processing change are practically negligible and this makes it possible to produce small batches ofslabs 1, at very competitive costs, with the most suitable interaxial distance between thechannels 3 for a specific project. - With respect to manufacturing with standard machinery, like for example hot wire pantographs for processing polystyrene, the method according to the present invention thus allows fast processing of the
slabs 1 at very low cost. The semi-finished block orpanel 106 runs in line in themachine 100 and meets the cutting dies, blades or punches 104, heated and preformed, which sublimate the EPS. In conventional pantographs, on the other hand, the panel is immobile and it is the standard tool that moves. The semi-finished block orpanel 106 can have any length. - The
machine 100 can produce even twoslabs 1 simultaneously, with all of thechannels 3, theribs 36, thethroats 38 and/or the grooves required, and therefore it has greater productivity than pantographs. Themachine 100 cannot be provided with programming, is simple to use and does not therefore require highly trained workers, or high programming and tuning costs. Themachine 100 is of small dimensions, so as to be able to be transported on a normal truck and positioned even on the building yard. The investment for making amachine 100 is less (roughly 50%) with respect to that necessary for a pantograph and is considerably less (more than ten times less) with respect to what is required to fit out a plant for moulding slabs made of EPS. - An example of application and use of the tailored-module system described above will now be illustrated. On a floor, foundation or base P suitable floor guides 7, which can for example be rods or bars with L-shaped cross-section, and the
fastening plates 9 to which to anchor the future load-bearing structure made of concrete or reinforced concrete inside theslabs 1 themselves, are fixed. Theslabs 1, with the relative guides 5 already mounted, are applied referring to the floor guides 7 and plumbed referring for example to theguides 5. Advantageously, theslabs 1 were produced with a height HL equal to that of the entire wall to be made, thus making it faster and easier to make the wall and substantially reducing the manual application operations. - Preferably, on top of the
modular slabs 1suitable lintel modules 8 are arranged, having the function of structurally connecting the concrete casts of the different pillars 13 to each other or to the cast of a second floor, foundation or base that must be supported by the pillars 13 themselves. - The
reinforcement cages 11 of the future pillars 13, i.e. the steel/wood bars or beams, are inserted from the top into therelative channels 5 and fixed to thefastening plates 9, after which the latter are filled with possible concrete casts, where foreseen. When the concrete has solidified, a composite wall is obtained, formed from theslabs 1 internally reinforced by a series of pillars 13 having the structural function both of supporting possible overlying structures, and of flexurally reinforcing the wall itself against possible knocking down. In order to reduce the risks of intrusion through the wall itself, the pillars 13 can be suitably close together and, by making them through cutting with hot wire, milling or drilling, thechannels 3 can be positioned in theslabs 1 with the interaxial distance most suitable for each installation and very low costs. - The composite wall can be finished by fixing for example panels made of plasterboard, wood or other coatings, or suitably plastered, to the
guides 5. -
Figure 5 relates to a slab 1' according to another embodiment not made according to the invention. The slab 1' is formed from many different materials: twoouter panels blocks outer panels blocks - With respect to the system with bricks or blocks described in document
EP 0 163 117 A1 , theslabs 1 can be applied with much less manual operations; moreover, thanks to their relatively large size, theslabs 1, 1' can be aligned and plumbed with greater ease and much greater precision; they reduce the number and overall extension of the slits through the layer of insulating material of the wall itself, thus increasing the impermeability thereof to air, humidity, to other atmospheric agents and to noise; they can be transported and moved much more easily on the building site, since the slabs are easier to hold, harness or bind, for example to be lifted with a hoist, with respect to an incoherent mass of insulating blocks in the form of bricks. Theslabs 1 made of EPS, XPS or other similar light materials eliminate very many problems of worker safety when they are moved on the building site. Moreover, the composite wall described above, in particular if made of EPS, XPS or other foamed plastic materials, is much lighter, less expensive and provided with much better thermal and sound insulation with respect to conventional walls made of solid reinforced concrete or of bricks, since on large portions thereof the entire thickness of such a composite wall is substantially occupied by just EPS or another insulating material. - The
slabs 1 are obtained from the cutting of blocks manufactured from EPS, XPS or other similar light and insulating materials. Such a processing procedure makes it possible to make any shape, size and interaxial distance of pillar (even round walls) and any size of panel without the typical constraints of moulding. Theslabs 1 are not therefore manufactured in series and there is not a limited choice of types of panels, sincesuch slabs 1 are made to size each time, adapting them to the architectural and structural design of the building. The cutting process also allows the insertion in the factory of accessories and personalisation, like for example home fittings, counterframes for doors and windows, shutter boxes, guides for rainscreens, plasterboard panels, etc., of any shape and size. It is also possible to make side panels for floors. - The embodiments described above can undergo different modifications and variations without however departing from the scope of protection of the present invention as defined in the appended claims. For example, a slab according to the invention can comprise a layer of foamed plastic material, like for example EPS or XPS, on which a panel made of wood or a wood-derived material is glued or in any case coupled. Moreover, all of the details can be replaced by technically equivalent elements. For example, the materials used, as well as the sizes, can be whatever according to the technical requirements. It should be understood that an expression of the type "A comprises B, C, D" or "A is formed from B, C, D" also comprises and describes the particular case in which "A consists of B, C, D". The examples and lists of possible variants of the present application should be considered to be non-exhaustive lists.
Claims (3)
- Method for producing a slab (1) made of insulating material for use in buildings, the method comprising the following steps:- arranging a work plane (102) on a machine (100);- arranging at least one cutting device (104) and heating it up to a temperature such as to be able to melt the insulating material;wherein said at least one cutting device (104) is fixed to the work plane (102), and wherein a semi-finished block or panel (106) made of insulating material is advanced over the work plane (102), according to a predetermined direction (F), through an advancing system provided on said machine (100), so that said semi-finished block or panel (106) hits said at least one cutting device (104) and so that said at least one cutting device (104) digs or cuts into the semi-finished block or panel (106) one or more of the following elements:- a passing channel (3),- a longitudinal rib (36),- a longitudinal groove, or- a longitudinal throat (38) configured to couple and constrain an edge of a first slab (1) to that of a second slab (1) analogous and adjacent to said first slab (1).
- Method according to claim 1, characterised in that the cutting device (104) is selected from the group consisting of:- at least one hot wire,- at least one cutting die,- at least one blade,- at least one punch.
- Method according to claim 1 or 2, wherein the position of said at least one cutting device (104) on the work plane (102) is variable in a direction parallel to said work plane (102), so as to vary the interaxial distance between said one or more dug or cut elements in the semi-finished block or panel (106).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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ITMI20140447 | 2014-03-18 | ||
PCT/IB2015/051954 WO2015140715A1 (en) | 2014-03-18 | 2015-03-17 | Method for producing a slab of insulating material for use in buildings, tailored-module system comprising such a slab and method for making a composite wall using such a slab |
Publications (2)
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EP3119947A1 EP3119947A1 (en) | 2017-01-25 |
EP3119947B1 true EP3119947B1 (en) | 2021-03-10 |
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EP15718604.0A Active EP3119947B1 (en) | 2014-03-18 | 2015-03-17 | Method for producing a slab of insulating material for use in buildings |
Country Status (3)
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EP (1) | EP3119947B1 (en) |
ES (1) | ES2874905T3 (en) |
WO (1) | WO2015140715A1 (en) |
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AT518375B1 (en) * | 2016-02-19 | 2018-10-15 | Austrotherm Gmbh | Process for producing a component made of polystyrene |
WO2017210717A1 (en) * | 2016-06-11 | 2017-12-14 | Sea To Summit Pty Ltd | Horizontally cored object and apparatus and method of producing same |
CN109424120B (en) * | 2017-08-23 | 2020-11-03 | 徐广鑫 | Steel construction wallboard |
JP2020124788A (en) * | 2019-02-06 | 2020-08-20 | 旭化成建材株式会社 | Method for manufacturing long-sized heat insulation material |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
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IT1209539B (en) | 1984-04-26 | 1989-08-30 | G P E Generale Polistirolo Esp | IMPROVEMENT IN THE FORMATION OF MODULAR ELEMENTS FOR THE ERECTION OF BUILDING STRUCTURES PREVALENTLY IN REINFORCED CONCRETE AND HIGH PROPERTIES OF THERMAL AND / OR ACOUSTIC INSULATION, AND SINGLE OR MULTIPLE ELEMENTS FOR THE FORMATION OF INTERNAL AND EXTERNAL PARTS HAVING THEIR PROPERTIES. |
US5465542A (en) * | 1992-05-29 | 1995-11-14 | Terry; Verl O. | Interblocking concrete form modules |
US5645542A (en) | 1994-12-29 | 1997-07-08 | Kimberly-Clark Worldwide, Inc. | Elastomeric absorbent structure |
US5943775A (en) * | 1995-11-13 | 1999-08-31 | Qb Technology | Synthetic panel and method |
DE10251286A1 (en) | 2002-11-04 | 2004-05-19 | Wahls, Manfred, Dipl.-Ing. | Wall structure, for buildings, has openings to take prefabricated polystyrene insulation cores together with structured recesses and openings for the plaster laths and reinforcements and the like |
US8359808B2 (en) | 2009-11-16 | 2013-01-29 | Solid Green Developments, LLC | Polystyrene wall, system, and method for use in an insulated foam building |
-
2015
- 2015-03-17 WO PCT/IB2015/051954 patent/WO2015140715A1/en active Application Filing
- 2015-03-17 EP EP15718604.0A patent/EP3119947B1/en active Active
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