IL36090A - Panel for building purposes - Google Patents

Description

PANEL FOR BUILDING PURPOSES This invention relates to a method for the manufacture of panels for use in building which are destined to be combined with carrying structures for the erection of e.g. floors, false ceilings, ceilings or roofs wherein a material having a high resistance to tension and/or high elasticity is used and another material having low resistance to tension and/or low elasticity, the said material being pourable and hardenable.

It is already known to manufacture shaped bodies of concrete which have an internal rein orcement consisting of steel rods or steel wire mats such as for instance fiat panels which are mainly exposed to bending stresses. It is further well known to compact such bodies by vibration or pressure exerted on the concrete prior to the hardening and setting of the latter and finally it is known to apply heat for acceleration of curing. In order to obtain satisfactory strength in the bodies it is necessary to place the steel reinforcement as uniformally as possible within the cross sectional area of the panel. This , however , causes certain di iculties, especially in panels of large dimensions and being of small thickness, since during the compacting of the concrete the reinforcement is easily displaced and for this reason it is necessary to provide special holding arrangements for the reinforcement, within the mo¾ds. Moreover in a rein-foeernent which is embedded in the concrete the rein-foeement which is positioned in the tension zone of Moreover those concrete panels which are manu- v factured in the conventional way are rather thick which is a consequence of the embedded reinforcement and obviously they are heavy weighted so that for many purposes they are not suited, or at least are not economical. Furthermore these conventionally reinforced concrete panels cannot be supported at the corners alone, since the reinforcement usually does not extend into the corners and therefore the respective forces of support are not transmitted directly into the rein orcement.

A further disadvantage of the known methods for the manufacture of concrete panels resided therein that the exactitude - as far as dimensions are concerned - of the final products are not sufficient for many purposes. Furthermore it is necessary e.g. in the case of spatial skeletons and false ceilings for the electric conduits in electronic computer plants, switch assemblies and like cases to form the panels as roof or even floor elements which have to take both bending stresses as well as tensional and pressure stresses in the plane of the panel itself so as to be able to bring about the necessary connect! between the building panels and the rod elements of the spatial skeleton or the carrying structure of false ceilings. It is a pre-condition for the attainment of this connection that there is sufficient exactitude of the plates as it is common with metal structural parts (e.g. in the magnitude of * 0.2 mm). The condition of a relatively high exactitude must such elements In great quantities, since otherwise it would be questionable whether such elements could be used to a great extent. The manufacturing cost of the individual panels therefore should be as low as possible.

Xn many cases, such as in the use of the panels in the erection of scaffoldings or in constructing platforms for workers servicing aircraft, the panels must not only be combinable with standardized structural parts of steel or like metal so as to be able to set them up and dismount them frequently, but they have to be of light weight and must be unaffected by being knocked about during transport so that the edges of the elements do not become damaged* The pre abricated panels for building constructions or those made of concrete, such as so-called sandwich elements, do not fulfill the above-named desiderata} also prefabricated panels manufactured from reinforced concrete or synthetic material or Bibrous matter with a binder of synthetic resins do not comply with the requirements stated above.

Thus the invention seeks to fulfill the task of finding an economical method for the manufacture of building elements to be combined with carrying structures which obviates the difficulties of embedding the reinforcement and which makes it possible to manufacture large sized building plates with highly exact dimensions and which - as compared with the known panels - are of better qualities and strength and of smaller thickness and which thanks to the high exactitude of their dimensions can easily be combined with standardized building elements of steel and light metal for the erection of various structures. According to the invention this task is s& ved thereby that the material with the high tensional resistance and/or high elasticity is formed into a thin -walled tray open at the top and thereafter the pourable or flowable material with the low tensional resistance and/or low elasticity is introduced into the tray in measured quantities and is thereafter compacted within the tray and hardened so that it forms a unit with the tray and the tray serves as an external rein orcement. By the* term "measured1* introduction of material it should be understood that material of a predetermined quantity is introduced into the tray, the theoretically required quantity being exceeded or less than the theoretical quantity being taken.

The external reinforcement does away with the hitherto required holders for the internal rein- cement. Thereby that the external einforcement i- J.** eSiS-molded and advantageously together with the required anchoring points for the carrying sub-construction the necessary exactitude of the panels is attained so that it can easily be used in combination with standardized building elements of steel or light metal. In this way a synergism of forces between the carrying structure (skeleton of steel or light metal) and the panels is attained. In other words, a building element manufactured according to the invention has - - exact external dimensions and exactly positioned anchoring points for the sub-s ructure* Xn an advantageous manner the pourable material with the low tensional capacity and low elasticity is compacted and hardened in the tray itself whereby a good connection between the two elements is stained and which is further improved by anchoring points (known per se) in the tray. In an advantageous manner, and pssferably. the anchoring points for the two above mentioned purposes are provided during molding of the tray. A panel made according to the invention, although being of relatively low thickness and low weight, is of high strength. The pourable material may be - according to the purpose of the element - concrete, or mineral substances with cement binder (including gas-concrete), gypsum or minerals bonded by gypsum, synthetic resins, organic fibres with synthetic resin binders, synthetic resin masses with embedded fillers such as cellular concrete, or "Perlite", wood concrete made of wood fibres and cement, asbestos-cement or the like more. The combinations which are usually made up into so called artificial stone can be used for that purpose. The tray may be made of steel, galvanized steel or steel sheet with an anticorrosive layer and/or synthetic resin coating of one surface, light metal alloys, moulded synthetic resin of high tensional capacity such as fibreglass.

In another practical form of the inventio the pourable material may be introduced in a quantity which exceeds the quantity actually required even after hardening; the exact thickness may be obtained by scraping or pressing off the excess. By the latter operational step another and additional compacting of the material and smoothening of the upper surface is attained .

The pourable material may be introduced into the tray in a quantity exceeding the actually necessary quantity and the quantitative measure may be attained thereby that part of the surplus is pressed out through openings in the tray. The openings may preferably be those which are used as anchoring points.

The pourable material may also be introduced in a quantity which is less than the required one, but the dimensioning during compacting may be attained by creating cavities in the material itself. A further feature of the invention resides therein that the pourable material is pre-corupacted in the tray and simultaneously anchoring openings are pressed into the material of the tray; the pressure tools for compacting are introduced through the said apertures and after compacting are retracted therefrom. This arrangement has the advantage that the pressure tools perform two functions one after the other t thereby that first they press the anchoring openings in the tray and then penetrate into the material so as to compact the latter.

Advantageously the compacting and/or hardening of the pourable material is performed in the tray simultaneously with the application of heat. This shortens the manu acturing time of the element as a whole.

During the compacting of the pourable material compensating layers of small thickness consisting of an expandable material which is blown up by pressure and heat and which consists of a hardenable synthetic resin of t e like more may be provided. This compensating layer offers the further possibility that the height (thickness of the panels) can be fixed with high exactitudes.

The invention will now be described with reference to the annexed drawings in connection with several executional examples.

In the annexed drawings Figs. 1, 2, 3 and k are sectional views illustrating the individual steps of the manu cturing process.

Bigs. 5 and 6 are fractional views illustrating a number of steps further executional examples.

Figs. and 8 are similar to Figs. 3 and t but show a slightly varied tray-shaped reinforcement.

Fig. 9 shows in a fractional section a panel according to the invention and serving as a building element.

Figs. 10 and 10a are sectional views of a panel according to the invention which is intended to serve as a wall element attached to a carrying skeleton.

As already indicated the new method may be performed with different materials* For the sake of simplicity the invention will now be described with the use of concrete as material of low tensional capacity and low elasticity and steel being the material with high tensional capacity and high elasticity.

The tray 1 is pre-shaped of a thin steel plate, say by shape-pressing it and at the same time anchoring points for the concrete 3 are provided in the shape of apertures 2 which have inwardly drawn edges. In the same step there are provided anchoring-? in the tray which are not shown in Figs. 1 and 2 and which serve for connecting the panels to a sub-structu e not shown.

Into the tray I, according to Fig. 1 concrete 3 is poured with a slight excess. The tray 1 is then placed on a vibrating table h wher&in the compacting of the concrete 3 is attained. Surplus of concrete marked 3* (according 6o figure 2) is removed by means of a scraper 5 so as to attain a smooth and at the same time compacted concrete surface 6. Instead of the scraper blade 5 shown in Fig. 2 a roller shaped scraper may be used (not shown) which is especially suited for use in the manufacture of long panels and which also results in an additional compacting and smoothing of the concrete surface. After compacting and hardening of the concrete the latter forms a unit with the tray and the tray serves as an external reinforcement which also guarantees the necessary exactitude of dimensions of the ready panel. Concrete which penetrated into the apertures 2 forms conical anohoring points which improve the capacity for connection with the carrying structure* Xn the embodiment shown in Pigs. 3 an 4 the ' tray 1 is placed in the mo|.d 7 which has an appropriate cross sectional form and thereafter concrete 3 is filled into the tray with a slight excess. By lowering the ram 8 the concrete 3 is compacted and simultaneously therewith the surplus of concrete is pressed out through the apertures 2 and registering openings 9 n the bottom of the mold 7· Thus the quantitative determination of the concrete mass is performed here during its compacting so that the initially poured in quantity is of no great importance .

It is also possible to pour in concrete at a quantity which is less than the required one and the exact quantitative determination and the compacting is attained by forming cavities within the coocrete mass (these cavities are not shown in the drawing). Such cavities may be attained thereby that after the lowering of the ram 8 into the position shown in Fig. additional pressure tools (not shown) are introduced through the openings 9 and 2 into the concrete 3· According to the embodiments of Figs. 5 a d 6 the shaped tray 100 without openings 2 is placed into the mold 10 and subsequently concrete 3 at a quantity less than that required for filling the tray is introduced. It should be observed that the anchorings (which are not shown) for the Sub-structure are already formed during the shaping of the tray. Then the ram 11 is lowered into the position shown in Fig. 6 whereby the concrete is subjected to a pre-compacting. Subsequently apertures 2 are made in the bottom of the tray by introducing tools 12 through the bottom of the mold, the tools 12 then penetrate through the openings 2 into the concrete for fully compacting the latter and after compacting they are retrieved from the openings.

Thereby the cavities 120 are formed in the concrete.

In the example according to Figs. 7 and 8 a tray la is used which is provided with a circumferential f lange 13 and which already has anchoring flaps Ik for the concrete 3· The tray 1 is placed into an appropriately shaped mould 15 and concrete is poured into it with a slight excess. The compacting of the concrete is performed after lowering ft£ the ram l6 in Fig* 8 with the interposition of a cover plate 17· Surplus of concrete is pressed out of openings Id which come into existence when the flaps 14 are punched inwardly, the concrete escaping through the registering openings 19 in the bottom of the mould 15 as shown in Fig. 8. The covering plate .17 may then be connected in whatever conventional way wit th©flange 13. The covering plate may serve* depending on the material used, either for aesthetical reasons only improving the exterior appearance of the panel or it may form a compensating layer which can take additional static functions. Thus, if for instance the covering plate is a plane steel sheet the panel will be all around closed. In this case the covering plate can take horizontal stresses in the plane of the panel or parallel to ttie latter.

Anchoring points formed during the shaping of the tray la are not shown in Figs. 7 an 8.

Instead of the steps mentioned above and in order to attain exact dimensions of the concrete filling 3 and thus of the height of the finished panel it is possible even at a quantity of concrete which is less than the required quantity, to provide during the precompacting of the concrete at one side thereof a compensating layer of small thickness which under application of pressure or heat is blown up and hardens. Thus in this case *he exact height of the finished element is determined by the compensating layer which is level with the circumferential flange or the upper edge of the tray.

Pig. 9 shows an executional form of the invention whereby the panel is to be used for a double floor.

The panel in this case must have exact exterior dimensions with tolerances of + 0 , 2 mm. which can be attained by exactly perpendicularly drawn up walls 20 of the tray 101, At the same time when shaping the tray 101 the anchoring openings 21 are provided at exactly predetermined points in which openings, during assembling the construction spigots 22 of supporting legs 222 enter. Here, in this case there is also attained automatically an exact orientation of the element since the openings of the tray according to the invention had been attained in a most exact manner in an economical manufacturing process. When compacting the concrete cavities 23 are provided in a conventional manner in the concrete so as to provide space for the spigots 22 of the supporting legs. The flaps Ik contribute to the connection between the tray 101 and the concrete 3.

Figs. 10 and 10a show a further embodiment of ceilings in a special skeleton comprising connecting elements 24 and rods 25. the panel again comprises a tray 102 with an embedded anchoring screw bolt 26 for the concrete 3 and a circumferential flange 13* in wBiich latter there have also been pressed anchoring openings 27 for screws or bolts. According to Fig. lOa the panel is provided additionally with a covering plate 17 according to Fig. 8 which has apertures 27 in register with openings 29 for the passage of screw bolts 28. The screw bolts 28 are screwed into the connecting pieces 24 when the panels are placed on supporting plates 3° which latter press on connectors 24. In this executionai form of the panel it is not necessary that the flange 30* is of high exactitude* , since the connection beti?een the panels and the carrying structure is ittai-m&d by means of the bolts 28. With the aid of the bolts and the exactly placed openings 27 an exact orientation of the panel within the spatial skeleton is attained and furthermore it becomes possible to transmit forces which act perpendicularly on the panel and furthermore horizontally acting tensional or pressure stresses (occurring in the plane of the panel or parallel thereto) by transmitting these from the connecting pieces onto the panel or from the panel onto the connecting pieces. It must be emphasized here that the n&eithod according to the invention makes it possible to prepare the panels in an economical manner and in a way which warrants the proper effect of the connections between the panels and the spatial skeleton.

From the above examples it will be seen that the placement of the apertures in the tray is of great the case of double floors, the exterior dimensions of the ready panel must be kept in very strict limits. By a pre-shapLng, e.g. forming of the tray by pressing it, the latter forming the exterior reinforcement of the ready panel, the above conditions can ba fulfilled most easily.

Claims (6)

1. WHAT IS CLAIMED IS : 1.
2. A method for the manufacture off composite, slab plate shaped elements for use in the constructions of ceilings* false ceilings, roofs and the like more, wherein into a concavity formed by a first material having high resistance to tensional stresses and/or being highly elastic e.g. steel sheet there is introduced a second material with low resistance to tensional stresses and low elasticity e.g. concrete, the said first material serving as a reinforcement of the plate or slab element characterised thereby that the first material with the high tensional capacity is farmed into a thin-walled tray open at top, quantity of the second pourable material having low tensional capacity and low elasticity being introduced into the tray corresponding approximately to the holding volume of the tray and is subsequently at least pre-compaeted within the tray, the said pourable material being then brought to the desired volume during or after compacting. ' 2.
3. The method of Claim 1 characterised thereby that th® second material is introduced into the tray in a slightly excessive quantity and after compacting surplus of materials scraped off or squeezed off. 3« The method of Claim 1 characterised thereby that the second material Introduced is into the tray with a email quantit tive excess and the excess is removed tvom the tray through openings provided therein. h.
4. The raetKod ©f Claim 1 characterised thareby that of the second material there is introduced into the tray a quantity slightly less than required and subsequentl cavities or recesses are formed within the material within the tra . 36090/2
5. 5. The method of Claims 1 and 4 characterized thereby that the second material is precompacted within the tray and thereafter anchoring openings are punched into the walls of the tray and compacting tools are introduced through these openings for compacting the material and the tools are then retracted on the compacting.
6. 6. The method o? claim 1» wherein the pourable material is pre-compacted, characterised thereby that the pourable Material is introduced 4nto the ¾ray a slightly smaller quantity than required for filling the tray, a compensating layer of small thickness consisting of a synthetlo resin which at application of heat is blown up however, being bound to the pourable material during the compacting* 7· panels whenever obtained &m accordance with al or any of the preceding claims. 8* Method for the manufacture of building panels, substantiall as hereinbefore described and with reference to the annexed drawings. •4-