FI84927B - VAEGGELEMENT MED SKUMPLASTISOLERING OCH DESS TILLVERKNINGSMETOD. - Google Patents

Abstract

A wallpanel of the type having two outer sheathing boards (10, 11) separated by a rigid foam insulation (12) has a continuous top header (14) and a base reinforcement (22) which are each also formed of two boards (16, 24) separated by rigid foam insulation. Vertical stud members (30) formed of elongated boards having a central web (31) extending between the boards of the top header and of the base reinforcement, and have side flanges (32) nailed and bonded to the sheathing boards and extending between the bottom of the header and the top of the base reinforcement. The stud flanges allow nails to be applied internally of a flange into a first of the outer sheathing boards. The wall panels may have window and door openings cut out underneath the header after the foam has hardened between the panels.

Description

84927 CELLULAR INSULATED WALL ELEMENT AND ITS MANUFACTURING METHOD

The present invention relates to wall elements and a method of manufacturing them for buildings and in particular for residential houses, these elements comprising two external cover plates separated by hard foam insulation.

In many of the previously known elements of this type, wooden dowel pins connect the cover plates together to form thermal bridges which degrade the insulating capacity of the elements. Attempts have been made to avoid such thermal bridges, and such structures are disclosed, for example, in Canadian Patent Publication Nos. 1,041,728, issued November 7, 1978 to Samuelsson and 1,124,482, issued June 1, 1982 to Slater, and U.S. Pat. in Patent Publication No. 4,329,827, issued May 18, 1982 to Thorn.

In some prior art structures, e.g., Larrow U.S. Pat. in U.S. Patent No. 4,269,006, these elements are relatively narrow and various elements are used for wall areas without openings, wall areas with windows, and door openings. In other proposals, e.g., Edgar U.S. Pat. in the proposal of Patent Publication No. 3,697,633. using relatively long elements (with a length "I greater than their height), in which case window and / or door openings; · forming a part in an element which also contains without openings:". In a typical known system using such long elements, a window or door opening is formed by pre-cutting suitable openings in the cover plates before the element is manufactured, placing the cover plates in a position separate from each other in a mold or suitable holding device and then making frames around the opening, "... so that when foam is injected between the plates, it does not leak into this opening. The manufacture of such a frame causes considerable" · "labor costs with respect to the elements thus made. U.S. Patent No. 4,147,004, issued 3. April To Day et al., the window openings are cut into a finished element, but they require subsequent framing.

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The invention is characterized by what is set forth in the characterizing parts of claims 1 and 4.

The present invention provides wall elements which are suitably durable and in which thermal bridges are minimized. The invention also allows the production of long wall elements into which windows and / or door openings can be cut if necessary without further framing, although it is recommended that large openings be formed by separate components above the door and above and below the window. In the panel according to the present invention, it is not necessary to frame the openings, because a continuous reinforcement extending over the entire length of the element is used, which is supported internally on the element by means of support members for minimal thermal bridge effect.

The upper edge of the small window opening may be positioned immediately below the reinforcement, with the reinforcement providing the only reinforcement for such an opening.

The web of each support member is preferably a plate with parallel sides dimensioned so that its end: extensions fit perpendicularly between a pair of top flanges and a pair of bottom flanges, the nailing flange and said opposite edge element being formed of strips of sheet material,. attached perpendicular to the outer edges of said web.

The invention will now be described with reference to the accompanying drawings, in which:

Figure 1 shows a vertical view of a part of a wall element connected to the end part of an adjacent element;

Figure 2 shows a vertical section of the wall element taken along line 2-2 of Figure 1;

Figure 3 shows a horizontal section of the two wall elements taken along line 3-3 of Figure 1; 3,84927

Figures 4A and 4B show top and edge views of the support member;

Figures 5A and 5B show top and side views of a wedge used to join wall panels together;

Figures 6A and 6B show exploded top and edge views of a wall spreader and related components;

Figure 7 shows a horizontal section of the corner element;

Figure 8 shows a panel for cutting into other component parts, including a wall spreader and a wedge;

Fig. 9A shows a wall section including a part of the door opening. . koa and part of the window opening;

Figures 9B, 9C, 9D and 9E show sections taken along lines 9B-9B, 9C - 9C, 9D-9D and 9E-9E of Figure 9, respectively; : *. Figure 10 shows a horizontal section of an alternative; Y corner structure;

Figure 11 shows a vertical section of the connection between the wall and the floor; . . Fig. 12 shows a vertical section of an element provided with a window opening; and

Fig. 13 shows an alternative form similar to Fig. 4a showing a first alternative of support members.

Figure 1 shows the end of one wall element A connected to an adjacent wall element B, this element B being provided with a window opening W. Vertical and horizontal sections of these elements are shown in Figures 2 and 3.

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As best seen in Figure 2, the wall element comprises two external cover plates 10 and 11, which are separated by a hard foam insulation 12. The panels 10 and 11 may be made of plywood or made of so-called directional fiberboard made of wood layers. The inner plate part 11 can also be formed of a soft material provided with a suitable surface material for the inner wall surfaces. The hard insulation is a foam material, preferably polyurethane.

Extending the entire length of the top of the element is a continuous reinforcement, indicated by the number 14, comprising two upper flanges 16 separated by a hard foam insulation 12. The flanges 16 are attached to the inner surfaces of the plates 10 and 11. Passing across the upper edges of the flanges 16 is a transverse web plate 18 which is also attached to the foam material 12? the second top plate 20 is inserted during the installation of the element, but it does not form an actual part of the element itself. As shown in Figure 1, the window opening W can be cut so that its upper end is immediately below the reinforcement 14, with a depth of this reinforcement of about 12 inches (305 millimeters) sufficient to support the loads on the top of the element on the window without the need for other reinforcement. However, in order to avoid wastage of material, it is recommended that • large window openings be formed at least by means of separate wall elements as described below.

The base reinforcement marked with the number 22 extends over the entire length of the element. This reinforcement is similar to the main plate and includes - - two lower plates 16 thicknesses of the upper flanges. These lower plates are again separated from each other by means of a rigid foam insulation 12 and attached to the cover plates 10 and 11, and provided with a base or web plate 26 placed below the lower edges of the lower flanges 24. This puff and reinforcement is usually .... 3-4 inches high (89 to 101 millimeters). An additional base plate 28 may also be used, but does not form an integral part of the element.

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The support members 30 extend upwardly between the top of the base reinforcement 26 and the bottom of the top web 18, spaced about two feet (610 millimeters) apart. These support members are shown separately in Figures 4A and 4B. Each support member comprises a central web 31 formed as a side-parallel plate and including extensions 31a which fit perpendicularly between the top flange pair 16 forming the top end plate and the bottom flange pair 24 forming the bottom reinforcement so that its ends abut against the webs 18 and 26. In the area between the lower edges of the upper flanges 16 and the upper edges of the lower flanges 24, flanges 32 run attached to the outer edges of the web so that the center of the support member forms a channel. The flanges 32 form portions between the edges of the web and the cover plates 10 and 11 having the same thickness as the top and bottom flanges, thus filling the spaces between the web 31 and the plates 10 and 11 and thus bridging the reinforcement of the gap between the top and bottom flanges. Both the web 31 and the flanges 32 are preferably cut from the same material as the cover plates, which is therefore the same thickness as the top and bottom flanges 16 and 24.

As shown in Figure 3, the side edges of the wall elements are provided with recesses formed by providing the plates. 10 and 11 with extensions 10a and 11a extending over the interiors of the elements and ensuring that the flanges projecting inwards from the web of support members at opposite ends of the element extend away from the ends of the element. As can be seen from Figures 1 and 3, these recesses can be used to connect the two panels end-to-end together in a so-called by means of a foam wedge 34 shown in Fig. 5. This foam wedge comprises two elongate plates 36 separated by a layer of hard cellular plastic insulation 37. The outer surfaces of the plates 36 fit tightly to the end portions 10a and 11a, and the wedge is secured to the plates of the end portions by screws.

In the preferred method of manufacturing the element, the first cover plate 10 is placed on a table. The first web (such as plate 18) is placed on the plate 10 vertically by means of a vertical flange attached to the side edge 6 84927 of the table. A first flange (such as a plate 16) is glued to the plate 10 with its outer edge positioned against the web 18. A second flange (such as plate 24) is placed adjacent the opposite edge of the plate 10 and glue is applied between these plates. The preformed support members are then placed and glued transversely to the plate 10 with the end portions of their web portions 31 extending over the plates 16 and 24, with one end of each support member abutting the web 18 and one end of each lower member flange 32 abutting the inner edge of the flange 16. The position of the flange 24 can be adjusted as needed (while the adhesive is still uncured) to move the inner end of this flange against the other end of the lowest flange 32. As shown in the figure, the outer support members are placed backwards from the end of the plate 10 so that their flanges are inwards from these ends. The positioned support members are secured to the plate 10 with nails using an angled nailing device internally attached to the lower flange 32 of the support member. The web 18 can then also be nailed to the support members and the plate 16.

The other flange plates 16 and 24 are then placed in the webs of the support members; · On top of the parts and glued and nailed to the support members, which [! ’. then the top plate 11 is placed on the supports and the flange plates are glued and nailed in place to the top flanges of the support members. The bottom support plate 26 can then be inserted and clamped to the support members and the web 18 nailed to the top plates 16 and 11.

It is clear that this procedure can be changed somewhat, and that in some cases gluing and nailing may not be necessary. It is also clear that nailing may involve galvanizing and that when referring to nailing it also means galvanizing. However, it is important that the element be strong enough before the foam is added so that it can be handled easily. For this reason, the support member 7 84927 is nailed both to the first plate 10, whereby nailing is performed internally from the support member, and also to the second plate 11 by external nailing. A flange, such as a flange 32, is required for internal nailing, but only an edge element capable of receiving nails and having a thickness of the plates 16 and 24 is required for external nailing. However, it is desirable that this edge element also forms a flange.

To add the foam material, a series of injection holes are drilled in the lower edge 26, one hole always being between each pair of adjacent support elements. Air holes are formed in both the top and bottom support plates.

The hollow element is then transferred to a press in which a stack of several elements is held between an upper and a lower rigid mounting plate, these plates being able to withstand the expansion forces of the foam. With these tiles in place, the foam is injected through the injection holes and the cavities between the supports are filled. Filling can be ensured by checking the air holes and / or: by precisely adjusting the amount of foam injected. The finished element is removed from the mounting plates after the cell has hardened.

Hereinafter, reference is made to support members running across the cover plates. Although this is a typical arrangement for elements that are longer than their height (eight feet, or 2.4 meters), the invention can also be used to make elements that are, for example, 16 feet (4.88 meters) high, with the height of the elements being greater than the width. In this case, of course, the support members extend in the direction of the longer dimension instead of in the "transverse" direction.

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Figures 6A and 6B show a simple wall widening component that can be used to extend a wall from about six inches (152 mm) to about two feet (610 mm). The thickness of the widening element is the same as that of the cellular plastic wedge shown in Fig. 5, so that it fits exactly inside the plate portions 10a, 11a of both wall plates. This wall spreader 38 comprises two rectangular inner plates 40, both the height of the wall elements and about two feet (610 mm) wide, the hard foam material 41 separating them and the support member 42 running along one edge thereof. This edge is similar to the center of the support 30 but narrower because the plates 40 are closer to each other than the plates 10 and 11. The flanges 42a of the support member 42 project inwardly away from the edge. The upper and lower edges of the spreader are closed by plates 44 and 45, and in addition, the upper and lower plates 46 and 47 can be provided on site. The spreader also includes two plate portions 49 which abut the element cover plates and increase the thickness of the spreader to the thickness of the elements, and these outer plates can be cut to the desired width and placed between the edges of the two elements joined by the spreader to form a smooth joint. Figure 7 shows a corner element set to join together two wall elements of the type described. This • corner element includes outer and inner cover plates 52 and 53, which are similar to the cover plates of the wall element and equidistant from each other, and which are both. . also contain two halves connected perpendicularly to each other. The plate portions 55 reinforce the corners formed by both the outer and inner cover plates. The support members 57 include a web 57a and flanges 57b, similar to the corresponding portions of the center portion of the support 30, spaced apart from the outer edges of these plates for use with a foam to attach a corner element to an adjacent wall element. The spaces between the plates 52, 53 and the supports 57 are filled with hard insulating foam 58.

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Figure 8 shows a section of an element used as an intermediate step in the manufacture of various components such as a wall expander and a foam wedge. As shown, this element includes two cover plates 60 spaced apart for mating between the plate members 10a, 11a and including a support member 42 at each end, each of which is the same as the member 42 of Figure 6A. The center of the element is filled with a hard foam mass 62. Figure 8 shows how the element can be divided to form the following parts: A: a wall dilator part 38 which is the same as the main part of the wall dilator of Fig. 6A (i.e. without plates 49) and which can also be cut with parallel tops. and provided with lower edges to form an upper plate element as described below; B. Foam 34; and C. A filling element 64 which can be placed between the edges 10a and 11a of the wall element • with the support web facing outwards to close the end of the wall element.

I Figure 9A shows how components of the type described can be used to frame a door or window. Although, as described above, the continuous main plate allows openings to be cut in the element at any point below the main plate, the arrangement of Figure 9 is desirable except for small window openings.

As shown in the figure, the side of the door opening D is framed by a filling element 64 placed between the expanded plate edges 10a and 11a of the wall element, whereby the end of the wall element becomes substantially flat, largely formed by the web portion of the support member 42. This filling element also supports the main plate element 38a, which is in fact a horizontal block of the wall spreader 38 formed of the panel of Fig. 8. Each end of this main plate is placed between the edges 10a and 11a of the element plate on top of the filling element 64. The main plate includes outer plate portions 49a corresponding to the plate portions 49 of the wall applicator and bridging the gaps between adjacent edges of the cover plates of the wall element.

The structure on the top and side of the window opening W is similar to the structure on the top and side of the door opening. The part of the wall element below the window is cut to a suitable height and connected to each adjacent wall element by means of a wedge 34 as shown in Fig. 9E.

Fig. 10 shows an alternative corner solution in which no special corner element is required, but instead the wall spreader according to Fig. 6 is used. In this construction, the first wall element C is manufactured by cutting off its protruding plate edges 10a and 11a to expose the web 31 of the support member. A wall extender 38 of the second element F is placed in its edge recess and a support member 42 at its outer end. The expander can be cut to a width corresponding to each construction type. The opposite plates 49 of the spreader are then cut so that the inner plate bridges the gap between the edge of the cover plate 11 of the element F and the associated inner surface of the element C, and the outer plate of the wall spreader is cut so as to overlap the element C to form a smooth connection with the cover plate 10. The outer plate is then fixed in place with screws as shown and the screws are also inserted through element C inside the end of the wall spreader.

• "Figure 11 shows the joints between the base of a standard wall element,: Y the edge part of the floor element and the base wall element, this base wall being similar to a standard wall element (although usually lower for setting * · on a concrete base wall). The floor element includes an upper and

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11,84927 lower cover plates 70 and 71, spaced apart by an edge structure formed by the outer and inner elongate plates 72 and 73, separated by a hard foam layer 75. The outer plate 76 is secured with screws around the edges of the floor element. The outer surface of the plate 76 is flush with the outer surfaces of the wall and bottom wall element plates 10, and these plates are joined together by means of metal connecting brackets 78 fixed to the plate parts by nails or screws.

Figure 12 shows how a standard window frame is fitted to a standard type wall element, with the frame coming just below the bottom of the reinforcement. The window frame 80 is provided with a metal or plastic nailing rib 82 that extends completely around the window to secure the window to the outer cover plate 10. The wood strips 84 on the inside of the window frame secure it to the lower edge of the outer reinforcement portion 49a. Because the reinforcement receives the forces applied to the top of the wall element, no additional framing is required around the window in addition to the standard window frames shown in the drawings.

A wall element of the type described can be used in conjunction with the floor element shown in Figure 11, the foam-insulated roof elements and the uninsulated inner wall elements. The roof elements are provided with external and internal cover plates, which are similar to the cover plates of the wall elements and are provided with stiffeners formed by plate parts placed perpendicular to the cover plates. The inner wall elements may comprise two cover plates, which may be made of gypsum, and their inner part is hollow and bounded by upper and lower closure elements, which may be similar to the base reinforcement 22 used in connection with the wall elements.

Fig. 13 shows a support member modified as in Fig. 4A, the flanges 32 'of which are thicker than the wall element plates 16, 84927 and 24, however provided with grooves, so that the flange portions 32' between the edges of the web 31 'and the cover plates are thick.

Claims (4)

A wall element having cover sheets (10, 11) and hardened foam insulation (12) and at the upper edge a reinforcement (14) which is the same length as the entire width of the element and formed by flanges (16) placed against the upper parts of the inner surfaces of the cover plates and of a body (18) on the upper edges of the flanges, the foam insulation being located between the flanges, characterized in that the lower edge of the wall element also has a reinforcement (22) consisting of two flanges (24). ), which are as thick as the upper flanges (16) and which are positioned against the lower portions of the cover plates (10, 11), and a body (26) which is below the lower edges of the flanges (24), and that the wall elements thereto have vertical, disc-made support members (30) consisting of the flanges (32) and the life (31) between them, the body having been extended on the upper and lower sides of the flanges so that the extensions (31a) fit between the upper flanges (16) supporting on the upper the life (18) and between the lower flanges (24) supporting the lower life (26), the flanges (32) and the parts of the flanges (32 ') belonging to the life (31') and the cover plates (10, 11) are as thick as the upper and lower flanges (16, 24) and abut on their lower and upper edges, and that all areas between the cover plates (10, 11) and the upper and lower flanges (16, 24) are filled with hardened foam insulation (12). Wall element according to claim 1, characterized in that the flanges (32) and the life (31) together form in the supporting member (30) a channel part which is directed inwardly in the vertical edges of the element, and that the grooves (31) are placed spaced from the vertical edges of the cover plates (10, 11). A wall element according to claims 1 or 2, characterized in that the upper flanges (16) and lower flanges (24) of the reinforcements (14, 22) and the life (31) and flanges (32) of the supporting members (30) are all formed of sheet material of the same thickness as the cover plates (10, 11). i6 84927 Method for manufacturing wall elements according to claim 1, which wall element has cover sheets (10, 11) and hardened foam plastic insulation (12), characterized in that the method comprises the following stages: the first cover plate (10) is placed on a substrate; the life plate (18) of the reinforcement (14) is placed upright on the cover plate (10) along its first side edge; ); the second flange plate (24) is placed next to the opposite edge of the cover plate; the support members (30) are positioned transversely between the flange discs (16, 24), each supporting member (30) containing a central body (31), the extensions (31a) of which extend on top of the flange discs (16), and a nailing flange (32) positioned against the cover plate ( 10) between the adjacent edges of the cover plates (16, 24), and a cantilever element (32) of the same width as the flange, which is on the opposite side of the body part (31) away from the nail flange (32), and the other the position of the flange discs (24) is adjusted as necessary so that the adjacent edges of the discs are inclined towards the nailing flange (32): each end; the nailing flange (32) of each support member (30) is nailed to the first cover plate (10); the third and fourth flange discs (16, 24) are placed in the body parts (31) of the supporting member (30) and the edges of the latter discs, which are separate from each other, are placed against the ends of the edge members (32) of the supporting members (30). ); - the second support plate (26) is placed against the free ends of the pin means (30) and the outer edges of the other flanges (24) and the life plates' 418, 26) are fixed in the support means (30) and in the flange discs (16, 24); the second cover plate (11) is placed on the third and fourth flanges (16, 24) as well as in the edge elements (32) of the support members (30) and nailed in the flanges (16, 24); the foam and ventilation heels are formed in a life plate (18, 26) between each adjacent support member pair (30) and the foam load material is injected into the well spaces between the support members (30) while the cover plates (10, 11) are held in place by the presser. wherein the foamed plastic material is such that solidifies to harden foam insulation.