GB2123048A

GB2123048A - Building board and its method of manufacture

Info

Publication number: GB2123048A
Application number: GB08216884A
Authority: GB
Inventors: Hong An Se; Hyok An Kyo
Original assignee: Individual
Current assignee: Individual
Priority date: 1982-06-10
Filing date: 1982-06-10
Publication date: 1984-01-25
Also published as: MY8800138A; GB2123048B

Abstract

A building board has an inner layer 11 of spongy plastics with reinforcing wires 17 arranged in a zig-zag manner and projecting on each side of the plastics, the wires 17 supporting respective wire grids 19, 19<1> at spacings M, M<1> from the layer 11, into which spacings M, M<1> cement mortar is poured to harden and thereby complete the board. Individual straight wires 17 are pushed through the inner layer 11 to build up the zig-zag pattern and the grids 19, 19<1> are then welded thereto. <IMAGE>

Description

SPECIFICATION Building board and its method of manufacture The present invention relates to a building board, to be used primarily for inner and outer walls and ceilings of buildings, with emphasis on higher efficiencies in anti-moisture, sound absorption and adiabatic insulation, and to its method of manufacture.

A similar building board, which is known from No. 38 1764 (Building Elements) of Japan's Utility Model Notice, is made of steam-hardened spongy concrete layers which are joined with adhesives or bonding agents. The inner layers consist of porous (spongy) plastics (synthetic resin) in which reinforced bars are laid on both sides. This building board, therefore, has a certain anti-moisture, sound absorption and adiabatic insulation effects. However, because of relative weakness of coherence between the concrete and plastic layers, there is potential danger of separation of these layers, and the procedural complexity of the adhesive process involved in bonding the layers together poses many practical difficulties. Furthermore, structural strength of the building board is insufficient.

To produce such board, complex machinery is needed to facilitate the laying of reinforced bars into the steam-hardened concrete layers.

The method of adhering concrete layers to both sides of the plastic layers is also considerably complex.

An object of the present invention is to provide and produce a simplified building board and with this object in view the present invention provides a building board comprising a spongy plastic, for example synthetic resin, inner layer and layers of cement mortar on both sides of the plastic layer, with vertical frames consisted of lower frames and supporting frames laid within these three layers.

The present invention also provides a method of manufacturing a building board wherein reinforcing wires of fixed length are inserted into a spongy plastic board in a zig-zag manner parts of the wires protruding from and being of the same length on both sides of the board and slanted in the same manner, and spaces between the upper and lower parts, and left and right thereof are maintained to be fixed.

The structural strength, both in the vertical and horizontal direction of the building board of the present invention is remarkably higher than that of known building boards, and along with the superior qualities of sound absorption, antimoisture and adiabatic insulation, the building board does not need complex production facilities, requiring only simple tools for its manufacture.

The invention will be described further, by way of example, with reference to the accompanying drawings in which: Fig. 1(A) is a perspective view of a preferred embodiment of the building board of the present invention; Fig. 1(B) is an enlarged cross-section on the line Z-Z of Fig. 1(A); Figs. 2(A) to (J) illustrate various stages in the method of manufacturing the board of Figs. 1(A) and 1(B) wherein for clarity Fig. 2(C') is a cross-section on the line a-a of Fig. 2(C); Fig. 2(C11) is a cross-section on the line b-b of Fig. 2(C); Figs. 2(D) and 2(F) are enlarged fragmentary views of part of the building board of Fig. 1; and Fig. 2(1') is a vertical section of the board of Fig. 2(1).

Referring to Fig. 1(A) and (B) the preferred board comprises layers of cement mortar 6, 6' on both sides of an inner layer of the spongy plastics 4. A square frame 2 composed of upper and lower frame members 1, 11 and a supporting frame member 3 are laid within the inner layer of the spongy plastics 4 and the layers of cement mortar 6, 61.

Mortar fills the spaces between the layer 4 and frame 2 part of which mortar is exposed on the surface of the plastics, where it dries and hardens.

The upper and lower frame members 1, 11 reinforce the layer of cement mortar 6, 6' and because the supporting frame member 3 vertically joins together the upper and lower layers of cement mortar 6, 6' with the inner layers of the spongy plastics 4 the degree of joining strength is very high, as if the three layers were completely combined into one single entity.

Furthermore, because the frame 2 is laid in the layer of cement mortar 6, 61 and the spongy plastics 4 in both horizontal and vertical directions, the structural strength in vertical and horizontal directions are simultaneously bolstered.

The method of making the building board of the invention is as follows: As shown by the Fig. 2(A), spongy plastic board 11 is put on a fixed frame 13 which has protruding hanging sills 12, 121 at both its inner sides.

Between space-adjusting bars 14, 14? fixed on both sides of the upper part of the fixed frame 13 a square bar 16 is inserted, inner and outer sides of which bar 16 have grooves 1 5 hollowed out in mutually reverse directions. Then, reinforcing steel wires 1 7 cut into certain fixed length, are pushed into the grooves 1 5 in a regular sequence, by means of either manual or mechanical processes.

At this phase, the uppermost part of the re inforcing steel wires 1 7 are put in line with the surface of the grooves 1 5. Thus, the uppermost part of the wires 1 7 penetrate through the spongy plastic board 11 and stop at the inner front part 131 of the fixed frame 13. This is shown in section in Fig. 2(C').

When alp the reinforcing wires 17 are pushed in in this way at the first line, the square bar 16 is re positioned so that outer grooves 15' now have to face inside, and are tightly inserted between the space-adjusting bars 14, 14'.

Once the grooves are slanted in reverse of the former position, when the reinforcing wires 1 7 are inserted into the grooves 15' and pushed in the same direction, the wires 1 7 penetrate the spongy plastic board 11 in opposite direction of the previous phase and are fixed thereto, as shown by the section of Fig. 2 (Cli).

When all the reinforcing wires 1 7 are inserted into the spongy plastic board 11 in the aforementioned way so that the slanted lines of the wires 1 7 face in mutually opposite directions, the wires 1 7 are accordingly arranged in a zig-zag fashion. Because the spaces between the spaceadjusting bars 14, 14lithe concave groove 1 5 and groove 1 51, which are formed in reverse slants on the front and rear sides of the square bar 16, are all the same, when all the reinforcing wires 17 are put into the spongy plastic board 11, as shown by Fig. 2(D) distance I equals distance 1'.

As shown by the Fig. 2(C), after the spongy plastic board 11 is taken out of the fixed frame 13, the board should be handled in the manner shown by Fig. 2(E), that is: firstly, after putting steel wire-screen 1 91 on square frame 18, spaceadjusting rods 20, 20' are fixed on the front and back parts of the surface of the wirescreen 191.

Then the spongy plastic board 11 is placed on the wire screen 1 91 and on the front and back parts of the surface of this board 11, two further rods 20, 201 are fixed. After placing a further wire-screen 19 on the rods 20, 201 a cover 181 is put on the square frame 1 8 for stabilization.

As shown by Fig. 2(F), the length and breadth of each mesh 1 9a of the wire-screen 19, 1 91 are made so that length L equals length L1.

As illustrated in Fig. 2(F), as L=L'=I=I', when the wire-screen 19 or 191 is laid against the upper part of the reinforcing wires 1 7 which are fixed in zig-zag form, the reinforcing wires 1 7 are placed in the midst of upper and lower sides 1 9b, 1 9c of the mesh 1 9a.

In this way the part R to be joined are formed.

Because the rods 20, 20' are laid on both sides of the spongy plastic board 11, a fixed space M or M1 is formed between the wire-screen 19 or 19' and the spongy plastic board 11.

After placing the square frame 18 in an outer frame 21 as shown in Fig. 2 using a spot welding gun 22, the frame 18 is welded to the outer frame 21 from both the front and behind of the outer frame 21. The part to be welded is the contacting point of the central part of the both sides 1 9b, 1 9c of the unit mesh 1 9a to the reinforcing wire 17.

Approximately one second is needed for the welding of one such unit.

After the welding is completed as described above, the cover 18' of the square frame 18 is lifted, as shown in Fig. 2(H). When the spaceadjusting rods 20, 20' are removed, a board as shown in perspective view in Fig. 2(1) and in cross-sectional view in Fig. 2(1') is produced.

Cement mortar is then poured into the spaces M, M' formed between the spongy plastic board 11 and respective wire screens 1 9 and 1 9. The cement eventually dries to form the completed building board P, as shown in sectional elevation in Fig. 2(J).

The manufacture of the building board in the way described above needs no large-scale production facilities. With simple tools and processes, highly effective sound-absorbing, moisture-proof and adiabatic building board can be produced.

Claims

1. A building board comprising a spongy plastic, for example synthetic resin, inner layer and layers of cement mortar on both sides of the plastic layer, with vertical frames consisted of lower frames and supporting frames laid within these three layers.

2. A method of manufacturing a building board wherein reinforcing wires of fixed length are inserted into a spongy plastic board in a zig-zag manner, parts of the wires protruding from and being of the same length on both sides of the boaid and slanted in the same manner, and spaces between the upper and lower parts, and left and right thereof are maintained to be fixed.

3. A method as claimed in claim 2 wherein wire screens are laid on both sides of the spongy plastic board, meshes of the wire screen having the same length as the length of the spaces between the upper and lower parts of the reinforcing wires and space-adjusting rods being placed in between the wire screens to keep the protruded neighbouring reinforcing wires in contact with the central part of both sides of the member.

4. A method as claimed in claim 2 or 3 wherein the reinforcing wires and the contacted part of both sides of the meshes are welded together.

5. A method as claimed in claim 2, 3 or 4 wherein the space-adjusting rods are removed.

6. A method as claimed in any of claims 2 to 5 wherein cement mortar is filled into spaces formed between the spongy plastic board and the wire-screens.

7. A method of manufacturing a building board substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

8. A building board substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.