GB2113268A - Improved sandwich wall structure and the method for constructing the same - Google Patents

Abstract

A sandwich type insulated wall having an internal framework formed by channel bars (1) and transverse members (4) bridging two adjacent channel bars, is constructed by firstly erecting a plurality of channel bars (1) to form the main skeleton, secondly filling up the spaces among the channel bars with pieces of resilient insulating material (2) by inserting their edges into the channels of these bars to secure in place, thirdly providing transverse members (4) at both sides of the insulating material and further mounting thereover wire panels (5) to cover the whole area of the wall, and finally grouting both sides of the so-formed structure to form two concrete crusts. <IMAGE>

Description

SPECIFICATION Improved sandwich wall structure and the method for constructing the same This invention relates to an improvement in wall and the method for constructing the same, and in particular, to that of sandwich-type wall.

A lately developed wall structure having a core of light, resilient insulating material and reinforced by a wire framework, such as what the U.S. Patent 3,305,991 and 3,555,131 disclosed. Although undeniably a revolutionizing improvement, still suffer several drawbacks. Typically, such walls are prefabricated rather than constructed in situ. By inserting elongate pieces of insulating material, e.g.

foamed polyphenylethylene, into a wire framework and grouting both sides of the so-formed entity with a proper thickness of cement. It is costly and takes much labor to fabricate the wire framework and locate the elongate pieces. Constrained by its inflexible specification, it is not adapted to the fenestration on such wall at desired sites with desired sizes and shapes. Since if the horizontal dimension of the windows or doors is not exactly the multipe of the width of an elongate piece, there will always exist a problem of "remainder". For example, if each elongate piece is two inch wide, and the optimal width of the window is two feet and three inch, there would leave one inch where the framework is cut and the elongate piece cannot be retained in place. Under such circumstance, the consideration of design always to the constraint of specification.Like problem exists in the joining of separate walls, and is even more serious here. Being prefabricated, a wall of this type cannot be made too large considering its transportability. Thus a comparatively large wall must be formed by joining several smaller such walls together to form an entity. Since the wire framework of the resulting wall is not an integral whole, the joining portions form the weak dead corners of the wall which is extremely susceptible to fracture or fissure. Therefore it is only adapted well to partition wall, but gives poor result when applied to outside wall. Also, the leftover cannot be utilized, and must be discarded, therefore causing considerable waste of material.Moreover, it is somewhat difficult and laborious to tunnel through the wall which contains several separate elongate insulating pieces to set pipes for supplying water, gas or for passing electricai cords.

Accordingly, its the object of this invention to provide an improved sandwich insulating wall to obviate or mitigate the disadvantages of such wall while keeping all the advantages thereof.

SUMMARY This invention relates to a method to construct a wall of improved structure. Firstly, a plurality of channel bars are spaced vertically and horizontally to form the backbone of the wall. Each of the oblong or square vacancies between spaced channel bars is filled with a whole piece of continuous insulating board of light, resilient material, for example, foamed polyphenylethylene, with at least one of the sides of the board fitted into the channels of the bars. Then fit a plurality of transverse members across each two spaced bar to further retain the piece therein. Then both sides of the planar structure thus formed are respectively panelled with a wire panel. Preferably, a clearance is left between the wire panels and the insulating board, and this is practically achieved by the wings of the bars and the transverse member.Finally, the structure is grouted by conventional means, thus finishing the construction. The thickness of grouting cement is practically 2.5 cm, thus the aforesaid clearance is preferably about half that much, i.e. 1.3 cm or so. Preferably, grouting is done twice instead of finished at one time to obtain a better result.

Other objects and advantages of the present invention will become more apparent to those persons skilled in this art to which the present invention concerns from the following description taken in conjunction with the accompanying drawings, wherein: BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a partially cutaway view of a wall according to this invention; Fig. 2 to Fig. 6 shows the sequence of assembling the wall, in which:: Fig. 2 is a graphical representation showing the insulating boards and channel bars; Fig. 3 is a perspective view showing the channel bar and bar coupler; Fig. 4 is a graphicai representation showing the framework formed by channel bars interconnected by means of the couplers; Fig. 5 shows the scene when the transverse members are mounted; Fig. 6 shows the scene when the wire panels are mounted; Fig. 6-1 is an enlarged view of an exemplary clip for securing the wire panels; Fig. 6-A is an elevational view showing the framework of channel bars in which there is reserved spaces for making a door and a window; Fig. 7 is a perspective view of a split channel bar of improved type; Fig. 8 is a sectional view showing the engagement of another improved type of channel bar and its corresponding coupler;; Fig. 9 is a perspective view of two H-channel bars and their corresponding coupler.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT Referring now to Fig. 1, there is shown a partially cutaway view of a wall according to this invention, in which part of the concrete crust is dismantled to reveal the internal structures. As shown in Fig. 2, to construct such a wall, first select a plurality of spaced channel bars (1) of proper length, and fit end caps (21) onto the upper and lower ends of the channel bars. Then erect these capped bars and fix them to the ceiling and the floor by rivetting or nailing it to the floor or roof truss or by other means through the end caps (2). In so doing, the framework of the wall is made an integral part of the framework of the whole building. Then fit insulating boards (2) of proper size and which coincidently and snugly fill up the vacant spaces between the spaced bars.Preferably, insulating boards (2) are formed by light, resilient material, e.g. foamed polyphenylethylene, and their thickness is substantially the width of the channel of channel bar (1).

Apart from the vertical installation of channels bars (1) as described hereinbefore, channel bars (1) can be horizontally mounted to bridge the spaced vertical channel bars (1) to reinforce the frame and to make the fenestration on the wall possible.

What are shown in Fig. 1 and Fig. 2 are merely a simplest prototype of channel bar(1), which has two flange-like wing portions (11) extending along the length of bar. However, to facilitate the assemblage of the elements, the channel and the wings are provided with a plurality of transversely running slots (12), (13), (14), in which slots (12), (13) are provided to receive the tongues (32) (33) of coupler (3), whereas slots (14) are provided to mount transverse members. To couple two channels bars perpendicularly, first insert the tongues (32), (33) of bar coupler (3) into corresponding slots (12), (13) and bend the middle tongue (32) and side tongues (33) in opposite directions (see Fig. 4) so as to secure coupler (3) to channel bar.Corresponding to the wing portions 1) of channel bar (1), the two sides of coupler (3) fold inwardly to define two open sleeves (31) which are adapted to receive the wing portions. To couple the channel bars, nest another channel bar into the coupler with their concave sides facing to the same direction. The site and number of such coupling may vary, depending on actual necessity. Desired channel bars are suitably cut into proper size before they are assembled and are jointed at desired sites. Coupler (1) may also be used as end cap by bending all its tongues in the same direction (See Fig. 4).

Transverse members (4) are slender metallic strips having thin end portions (41). They are mounted to the framework by inserting their ends into the slots (14) of the wing portion (11) of two spaced channel bars (1) at desired sites, and bending their ends to secure them in portion. Transverse member (4) has three functions. Firstly, it serves to interconnect the spaced channel bars. It is to the channel bar just as what the strut to the beam. Secondly, it contributes to retain the insulating board, and in cooperation with the wing portions of the channel bar, ensure the desired clearance between the insulating board and the wire panel so as to allow the wire panel to be thoroughly enclosed in the concrete layer to enhance its tolerance to stresses.Thirdly, in the first grouting, it functions as a buffer to load the weight of cement slurry to prevent the downward sliding thereof by gravitation.

The next step is to mount the wire panels to the two sides of the flat structure (See Fig. 6). Leaning against the outwardly extending wings (11) and the transverse members (4), the panels (5) are spaced apart from the insulating board (2) by a clearance which depends on the width of wings (11) and transverse members (4). To secure the wire panels in place, a J-shaped hook (6), which has a straight end and a curve-in end that defines a hook, is used. First locate a panel in desired position and push the straight end of hook (6) to pierce through insulating board with its curve end knuckling the wire panel, then bend the straight end emerging from the opposite side to hook the another wire panel at the opposite side of the wall.

To secure the wire panel to the channel bars, a plurality of slotted clips (7) are used (See Fig.

6-1). The slotted clips has a L-shaped slot which opens at one end to allow the entry of the wire panel.

All the aforesaid steps, except for fixing the bars to the ceiling or floor structure, can be conveniently done manually by a half-skilled or even unskilled worker without any special tools. Each individual member is light in weight, not exceeding a man's average ability of load, so that one can carry the members from one spot to another with ease.

The final step is to grout the structure by conventional means, e.g. by shotcrete grouting or by hand.

All of the foregoing bar couplers (3), transverse members (4) hooks (6) and clips (7) are merely examples to realize the manual assemblage, and are not themseives'restrictive nevertheless. Taking example for the clips (7), it can be structured to be adapted to insert into the slots'of the wing portions of the channel bars.

Referring to Fig. 6-A, to make doors or windows on the wall, the desired site is firstly outlined by proper channel bars to leave an empty space without insulating board to define a door or a window.

After the wire panel is mounted, the portion located over the empty space is cut off.

To cope with the different requirement of the strength of the wall, the design of this invention is highly flexible. Its strength may vary by changing the thickness or number of the channel bars or by properly selecting wire panels of different thickness or meshes.

To enhance the strength of channel bar, it can be modified to have a corrugated or pleated channel bed. (See Fig. 7). Also, the coupling effect will be considerably bettered if a narrow recess (111) is formed at the base of each wing portion (11) of the channel bar to receive the corresponding inwardly protruding flange (311) formed at the opening of the open sleeve (31) of bar coupler (3).

Channel bar (1 ) may be modified to have a H-shaped cross section instead of the U-shaped section as hereinbefore. This design is stronger and retains the insulating board better, for one such bar provides two channels rather than one. However, the shape of its coupler must be properly modified, too. And so is the end cap. Also, the modification of Fig. 8 can be applied to the H-shaped channel bar.

None of the conventional wall structures can be said ideal because they all suffer their respective defects. Brick wail lacks elasticity and is extremely vulnerable to shear. Reinforced concrete wall is costly and takes much time to build, because several kinds of skilled workers are indispensibly involved, including reinforcement rod setters, masons, concrete formers, brick layers and plasters. Therefore considerably increasing the cost of labor. Moreover, since the wall structures are heavy in weight, the resulting building necessitates a very strong foundation to withstand its formidable weight, and this indirectly increases the cost. Said yet-known sandwich type insulating walls, although free of these drawbacks, are nevertheless unsatisfactory because of their structural defects.To make the comparison between this invention and the prior art, their differences are summarized as follows: TABLE 1 Comparison betweein this invention and the prior art

This invention Prior Art 1. Way of Can be buiit up in situ Can only be pre-fabricated construction 2. Cost of: (A) Formation of Low High parts (B)Transportation Low High 3. Structure With a framework of With a framework, the channel bars, the abutment abutment of two adjacent of two adjacent insulating insulating pieces is a weak boards, where there lies a "dead corner", of the channel bar, makes the inner core.

strongest portion of the inner core.

4. Constraint The design is highly Highly specified material of design due flexible, not restricted by must be selected to match to specification specification. the design.

5. To build a large The whole wall forms an Several smaller walls are wall integral entity, leaving no joined together, leaving dead corner. their abutments the weakest portions.

6. Easiness of Very easy in cutting, Difficult to cut, fenestrate operation ~ fenestration and piping. or set pipes 7. Waste of Very little waste of Considerable useless material cutoff leftover 8. Scale up Very free, the structure can Very difficult in whatever be strengthened by varying height or width the number or thickness of channel bars Table 2 to 4 are the data of same tests of this invention.

TABLE 2 Test of the ability to withstand stress of a sample: 35.6 cm x 35.9 cm x 1 1.0 cm

1. Density (g/cm3) 1.347 2. Axial resistance to pressure 22,535 (kg/m) 3. Transverse resistance to 383,411 pressure (kg/m2) 4. Resistance to bending 27.0 TABLE 3 Axial Load Test

Sample Specification Maximal Load Deformation Max. Line (tons) at Maximal Load Load (mm) (ton/m) 1 63 x 96 (cm) 6.88 12.41 10.92 2 4x8 (ft) 18.85 21.36 14.64 3 4 x 8 (ft) 25.54 21.46 20.95 TABLE 4 Test of Resistance to Fire Sample: 30 x 30 x 1 Ocm (concrete crust thickness 2.5cm)

Test Temperature Temperature Heating Observed Result of the heating of the opposite time side (OC) side OC hour: minute First 100 - 0:20 No combustible burning gas is found 200 84 1:05 liberated during the burning. After 300 90 1:50 cooled, the heated side has very tiny 340 120 3:00 T-shaped fissure, but no flaking is observed Second 100 30 0:16 No combustible burning gas is found with the 200 40 0:30 liberated during sample the burning. Tiny enclosed by 300 90 0:55 fissures are found 3cm of, at both the heated glass wool 400 190 1:42 side and the back at four side, but no crack sides, and 440 300 2:17 or flaking is found.

by 6cm of glass wool 500 - 3:34 at the backside) 540 - 7:20 After cooled, apply load to its side (30 x 1 Ocm) The maximal load = 11,200 kg Resistance to pressure = 37.3 kg/cm2 (531 psi)

Claims (12)

1. A method for constructing a wall having a core of light, resilient, heat-insulating material with a framework of metallic bars and two wire-reinforced concrete crusts at both sides of said core, comprising: erecting a plurality oi bars each of which defines one channel or more channels and which are hereinafter referred to as channel bars, to construct a substantially planar framework and fixing the framework to the ceiling or floor structure of a building; filling the empty spaces among spaced bars with pieces of light, resilient heat-insulating material, which is hereinafter referred to as insulating board; subsequently mounting wire panels onto the two opposite sides of said insulating board, with a clearance between the wire panel and the insulating board; grouting the two panelled sides to form two concrete crusts.

2. The method according to Claim 1, wherein the framework of channel bars are constructed by vertically and horizontally spaced channel bars.

3. The method according to Claim 1 or Claim 2, further comprising mounting pieces of members, which are hereinafter referred to as transverse members, to said framework outside said insulating board to bridge each two spaced channel bars.

4. The method according to Claim 1 , wherein said channel bar has substantially U-shaped cross section.

5. The channel bar according to one of Claims 1 to 4, wherein said channel bar has two outwardly extending wings running along its length, and the width of each wing is substantially equal to the clearance between said wire panel and said insulating board.

6. The method according to Claim 1, further comprising means which joints two perpendicular channel bars together and which is hereinafter referred to as bar coupler; said bar coupler being shaped to define a channel at the middle portion, and two outwardly extending open sleeves so that said channel bar A can be received therein with its two wings inside said two open sleeves respectively.

7. The method according to Claim 1 or 6, wherein one end of said bar coupler forms two or more tongues, and corresponding to the tongues, there are slots traversing the channel bed of said channel bars, so that said tongues can be inserted into their corresponding slots and bent to degrees in two directions to secure said coupler to said channel bar.

8. The method according to claim 3, wherein the wings of said channel bars have spaced transverse slots, which allows the ends of said transverse member to be inserted thereinto.

9. The method according to Claim 1, wherein said wire panels are secured in position by members which pierce through said insulating board and the two ends of each of which defines two hooks respectively hang said two wire panels on the two opposite sides. and by a slotted clip, which has an open slot that allows the entry of a wire of the wire panel and which has a portion to hold itself to the channel bar so as to secure the wire panel to the channel bar.

10. The method according to one of Claim 1, Claim 4 or Claim 5, wherein the channel bed of said channel bar has a corrugated or pleated structure.

11. The method according to Claim 1, 4, 5, or 6, wherein each of the base of the wing of said channel bar forms a recess, and at the position corresponding to said recess the bar couple; forms a projection that can fit into said recess.

12. The method according to one of Claims 1 to 3, wherein said channel bar has a substantially H-shaped cross section.

1 3. The channel bar according to Claim 12, whereof one side has outwardly extending wings at both sides, of which the width is substantially equal to the clearance between said panel and said insulating board.

1 4. The slotted clip according to Claim 9 comprising two substantially C-shaped halves interconnected abreast at one end to define an open slot, of which the width is slightly larger than the diameter of the wire of the applied wire panel, and the close end, i.e. the interconnected end bends in to form a recess slightly broader than the thickness of said wings.

1 5. A method of constructing a wall and constructional parts for such a wall substantially as hereinbefore described with reference to the accompanying drawings.