ITVI990106A1 - MODULAR COMPONENT FOR THE CONSTRUCTION OF BUILDING STRUCTURES WITH UNIFORM INSULATION. - Google Patents

Abstract

A modular component for the production of building structures with uniform insulating properties comprises a substantially flat shaped modular insulating element (1, 20) made of thermoplastic material and with longitudinal side edges, joining means (7, 8, 7', 8') provided along said longitudinal side edges for coupling with similar adjacent modular elements so as to form a substantially continuous insulating panel which is devoid of thermal bridges, anchoring means (9, 10, 11, 12) provided on at least one large flat side of the modular element (1, 20) and extending along a direction that is substantially perpendicular to the plane on which the main modular element (1, 20) lies in order to allow its anchoring to a filling material (16, 16', 16'') of the wall structure. The modular element (1, 20) consists of a portion of thermoplastic material extrusion provided with at least one longitudinal compartment or cavity (2).

Description

DESCRIPTION

Field of application

The present invention relates to the sector of modular components for building structures, in particular of extruded thermoplastic components to be used as insulation and support elements in the on-site manufacture or prefabrication of infill panels for building.

State of the art

Conventional systems are known for the insulation of building and masonry structures or prefabricated concrete panels, essentially consisting of plates or layers of insulating materials, such as for example expanded polystyrene or polyurethane foam, placed inside the concrete casting or concrete.

The main drawback of these known insulation systems is that they do not allow a total elimination of thermal bridges due to the fact that, for static reasons, the prefabricated panels are at times interrupted by concrete ribs or supporting curbs. Condensation and mold often originate in correspondence with these interruptions. Furthermore, the polystyrene insulating panels can cause cracks and detachments on the filling material in which they are immersed.

A type of extruded thermoplastic vertical modular component with box section is also known, which can be connected to other similar elements to build complete walls, provided with a first series of hollow compartments suitable for receiving the poured concrete in place, as well as a second series of compartments placed parallel to the first ones and suitable for receiving an insulating material. In other words, this known modular component defines a sort of formwork for the structure to be built.

A modular component of this kind is described in the international patent application WO 97/32095.

The modular components of this type known from the state of the art are generally made of thermoplastic material and by extrusion of synthetic resins optionally filled with glass fibers or the like. Preferably the material used is of the fireproof type and the modular elements can be covered on the external face with layers of high resistance plastic material to improve their mechanical characteristics.

A drawback of these known components for building structures is their relative complexity which involves the use of rather complex extrusion processes and finishing processes for manufacturing the components. To obtain a good distribution of the concrete in the relative compartments of which these elements are composed, especially in the case of very long modular elements, it is necessary to obtain a certain number of openings in the partition walls of the compartments to make the concrete evenly distribute during the laying in Opera. All this increases the production costs of the components themselves.

A further drawback encountered in building constructions which use these known modular element components is that of presenting discontinuities in correspondence with the connection areas between adjacent panels, thus creating the possibility of infiltrations since the concrete is not continuous throughout its surface.

Other important disadvantages are closely related to the aesthetic appearance of the walls or other masonry structures built with these panels. In fact, after their installation, the main plastic faces remain on the outside, leaving visible discontinuities at the junction areas of the individual components.

Furthermore, in the event of a violent impact, for example by an industrial vehicle, against a wall of a warehouse built with these elements, the damage caused to the wall itself cannot be easily repaired with the conventional means used in the construction sector. Furthermore, the aforementioned components cannot be easily painted or whitewashed like masonry surfaces.

All these factors therefore contribute to limiting the diffusion on the market of these modular components to the traditional clientele made up of artisan and industrial companies.

In addition to the above, there is also a cultural phenomenon of public rejection of buildings constructed with such synthetic materials due to the fact that they give the unpleasant sensation of living inside a "plastic" box, and this it occurs more frequently in countries where the building material par excellence is traditionally of the stone type.

Description of the invention

The primary purpose of the present invention is to provide a modular component for the construction of masonry structures which makes it possible to obviate the aforementioned drawbacks and in particular which is easy to manufacture and install.

A particular object is to provide a modular component for the insulation of masonry structures which eliminates or at least reduces the thermal bridges between adjacent insulating panels, providing a masonry structure with substantially uniform insulation.

A further object is to provide a modular component that can be used to build prefabricated panels or masonry structures that have a finished appearance that is aesthetically more pleasing and acceptable to the public, being able to avoid surface finishes in which the plastic remains visible, if this is desired by the customer, and which also allows the walls to be repaired or restored more easily in the event of collisions and damage.

These objects, as well as others which will become more evident in the following, are achieved, in accordance with claim 1 by means of a modular component for uniform insulation of masonry structures, characterized in that it comprises a main body with a substantially flat development and with longitudinal end edges, said main body being provided with connection means arranged along said longitudinal edges for mutual coupling with similar adjacent modular components so as to define a substantially continuous insulating panel without thermal bridges, anchoring elements being formed on said main body for the '' stable anchoring to the mass of concrete or filling material of the wall structure in which the component is inserted.

Thanks to this configuration, the modular component makes it possible to create wall structures with substantially uniform insulation and no thermal bridges, with a lower cost for installation, a better aesthetic appearance of the finished structures, and greater ease of maintenance.

According to a further aspect of the invention, a method is provided for the production of masonry structures incorporating insulating panels obtained by assembling modular components of the type indicated above, which comprises the following steps:

a) assembly of at least one insulating panel of predetermined length obtained by reciprocally coupling a plurality of modular components according to one or more of claims 1 to 12;

b) provision of a formwork consisting of a pair of substantially parallel side walls and insertion of said at least one insulating panel in a substantially intermediate position between said side walls;

c) arrangement of any metal reinforcement elements such as bars, rods or nets in the areas or areas between said at least one insulating panel and the side walls of the formwork;

d) casting of concrete or other filling material into the cavities formed between said at least one insulating panel and the side walls of said formwork;

e) drying of the concrete;

f) dismantling of the formwork and exposure of the finished masonry structure.

Brief description of the drawings

Further characteristics and advantages of the invention will become more evident in the light of the following description of some preferred but not exclusive embodiments of a modular component for masonry structures with uniform insulation, illustrated by way of non-limiting example with the aid of the attached drawings , in which:

FIG. 1 represents a perspective view of a first embodiment of a modular component according to the invention before installation;

FIG. 2 shows a perspective view of a second embodiment of a modular component according to the invention before installation;

FIG. 3 shows a perspective view of a third embodiment of a modular component according to the invention before installation;

FIG. 4 represents a perspective view of a section of panel composed of the union of several modular structural components according to the invention before installation;

FIG. 5 represents a perspective view of a section of panel composed of the union of several structural elements according to a second embodiment of the invention before installation;

FIG. 6 represents a sectional view of a section of a wall structure made with modular components according to the first embodiment of Fig. 1;

FIG. 7 is a sectional view of a section of a variant of a wall structure made with modular components according to the second embodiment of Fig. 2;

FIG. 8 is a sectional view of a section of a further variant of a wall structure made with modular components according to the second embodiment of Fig. 2;

the F! G. 9 shows a sectional view of a third variant of a section of wall made with structural elements according to a third embodiment of the invention after installation.

FIG. 10 represents a perspective view of a wall structure made with a section of the panel shown in Fig. 4.

Description of some preferred embodiments

With particular reference to Figure 1, a first embodiment of the modular component according to the invention is illustrated, generally indicated with the reference number 1, essentially consisting of a section of extruded profile of a thermoplastic material, for example a resin of the PVC type. .

In general, the modular component 1 can have various sections and dimensions, depending on the type of construction to be carried out, and can be cut to size at the time of installation on site or in the workshop before being transported to the site.

Preferably, the modular component 1 comprises a central body 2 with a substantially flat development, having main faces 3, 4 substantially opposite and parallel to a main development plane H, joined by two end edges 5, 6 substantially perpendicular to the faces 3, 4 Thus, the faces 3, 4 and the edges 5, 6 will define an interspace 2 'which can be left empty or filled with an insulating material, for example a synthetic resin such as polystyrene or expanded polyurethane, in order to improve the properties of '' acoustic and / or thermal insulation of the component as a whole.

Each modular component 1 can be provided, along the end edges 5, 6, with respective connection means 7, 8 for mutual coupling with other similar components, indicated 1 ', 1 ", so as to be able to form an insulating panel P of indefinite dimensions, according to the needs, defining a substantially uniform and continuous insulation, without thermal bridges in the connection areas.

In a preferred embodiment, the connecting means 7, 8 may consist of male and female elements, respectively, which can be coupled by sliding. For example, at the end edge 5 longitudinal protrusions 1 \ 7 "can be provided, substantially opposite and insertable by sliding inside the grooves 8 \ 8" formed on the faces 3, 4 near the longitudinal end edge 6.

Alternatively, the connecting means 7, 8 may have any complementary shape as long as it is adapted to mutually interlock the adjacent modular components 1, 1 \ 1 ", along the respective longitudinal end edges.

According to the invention, the central body 2 is provided with elements for stable anchoring to the mass of the concrete or any other filling material which constitutes the wall structure.

In particular, the anchoring elements may consist of stiffening ribs 9, 10, 11, 12 which extend outwards starting from one or both main faces 3, 4 of the modular component in planes substantially perpendicular to the main development plane H and in the longitudinal direction. During the installation of the masonry elements M or in the phase of construction of prefabricated panels P, these ribs 9, 10, 11, 12 are immersed in the concrete

In turn, the ribs 9, 10, 11, 12 can be advantageously provided with longitudinal protrusions 13, 14, 14, 15 which extend in a plane substantially parallel to the main development plane H to improve the anchoring conditions and avoid the detachment of the concrete.

As illustrated in Fig. 2, the ribs 9, 10 can be made only on one face 3 of the body 2, should it be desired to leave the opposite face 4 without ribs visible.

It is also possible to arrange a variable number of ribs according to the needs, as it is also possible to vary the distance between the ribs and their width towards the outside.

Fig. 3 illustrates a variant embodiment of component 1 in which the ribs 9 and 10 are interrupted at intervals along their longitudinal development, to allow a better distribution of the concrete during casting, thus avoiding creating unsightly voids on the wall. It is also possible to make elements with both continuous and discontinuous ribs.

This embodiment is particularly suitable when it is necessary to position the component horizontally in the walls or transversely in the prefabricated panels.

Figures 4 and 5 schematically illustrate sections of panels P each formed by the assembly of several modular components 1, 1 ', 1 "which are joined by means of male and female connection means 7, 8. In this way it is possible to connect in a way stable a predetermined number of modular components by making an insulating panel P of desired width.

Fig. 6 shows a first embodiment variant of a wall by joining modular structural elements 1, which in this variant also contain insulating material in the interspace 2 '. The modular component 1 is positioned between the side walls of a traditional formwork, not shown in the drawings, into which the concrete 17 is cast and reinforced by iron bars or nets 18. In this way a compact wall structure M is created. , with a homogeneous external appearance and without external plastic surfaces. The wall structure M that results after dismantling the formwork has a more appreciable aesthetic appearance and can be more easily painted or finished as desired.

Furthermore, the wall insulation, achieved thanks to the air cavity or to the insulating material placed in the interspace 2 ', effectively insulates the two portions of concrete 17' and 17 ", eliminating any thermal bridge at the joints of the components of the panel P. Finally, the presence of the anchoring elements and the relative protrusions allows the positioning of the insulating panel P in an easy and precise way between the walls of the formwork.

A further advantage consists in the possibility of using even lower quality materials since after installation no part of the elements will be visible from the outside. Furthermore, such types of prefabricated panels or masonry structures are more easily accepted by the public due to the fact that they are more similar to traditional building structures.

Fig. 7 shows a further executive variant of a wall structure M in which the face 3 of the body 2 constitutes the surface of the insulating panel P destined to remain outside, while the opposite face 4 is destined to cooperate with the concrete . Such a solution can be advantageous when it is desired to exploit some of the characteristics of thermoplastic materials, such as resistance to bad weather, to obtain an external wall of a building with characteristics of high surface finish and stable pigmentation. In this case, a formwork consisting of a single interchangeable wall can be used to form the structure, while the second parallel wall consists of the same insulating panel P which serves to contain the concrete.

This variant is also very advantageous for the construction of covering surfaces for buildings or roofs of the ventilated or insulated type.

The third executive variant illustrated in Fig. 8 allows to obtain a wall structure M with both external surfaces consisting of the external surfaces of two panels P, P 'formed by respective modular components. The concrete is introduced into the cavity formed between the two panels P, P 'which act as an immovable formwork.

The fourth executive variant represented in Fig. 9 offers a solution for all cases in which high insulation characteristics of the masonry structure are not required. In this variant, in fact, the panels P "are composed of the union of components 20 which are substantially in the form of a plate rather than a box. Furthermore, the face 21 of the panel P" facing outwards consists of the external surface of the modular components 20.

In all cases in which the external surface or surfaces of the thermoplastic panels are left visible after installation, it is advisable to use thermoplastic materials that have properties of resistance to aging, fire or other aggressive agents.

Obviously, the structural elements can be manufactured with various dimensions and can be used both in a horizontal and vertical position according to the type of construction to be made.

The realization of the walls or masonry structures incorporating modular thermoplastic components according to the invention is carried out with one of the methods described below:

A panel P is first assembled by joining together a plurality of thermoplastic modular components 1 according to the invention. If necessary, panel P is cut to size. A formwork of a per se known type is then constructed, for example with walls made of plastic, wood or metal, into which the assembled panel P is inserted using the components 1 described above.

Metal reinforcements 18 of the round or mesh type are then arranged in the space between the panel P and the walls of the formwork and the concrete is poured into this same space. Wait for the time necessary for it to dry and finally dismantle the formwork. At the end of this process, a wall or masonry element of the type shown in Fig. 6 results.

In the event that one of the walls of the formwork is made with the panel composed of the modular elements according to the invention, the manufacturing method is similar to that already described, with the difference that, after the curing of the concrete, only the second wall of the formwork is being dismantled. The result is a wall or masonry element of the type illustrated in Figures 7 or 9.

If the masonry structure has both walls made up of panels Ρ ', P "obtained by assembling components 1 according to the invention, the difference with respect to the method described above consists in the fact that the walls of the formwork are both made of the same panels Ρ' , P "and therefore at the end of the process the formwork will not have to be dismantled, but is an integral part of the wall structure.

The manufacturing process of precast concrete panels incorporating thermoplastic modular components according to the invention can be as follows.

A first layer of concrete is initially laid on the traditional tops or tables for the production of prefabricated panels, preferably of the vibrated type, arranged horizontally. This is followed by the laying, in a horizontal position, of a metal mesh or other suitable reinforcement element on the concrete layer.

A second layer of concrete is then laid on which a panel P formed by the union of a plurality of modular components is then laid. The P panel is adjusted so as to immerse the ribs 9, 10, 11, 12 in the concrete to promote anchoring.

A third layer of concrete is then poured, at least thick enough to cover the ribs 9, 10, 11, 12. The mesh or other reinforcing elements of the concrete are then laid and finally covered with the quantity of concrete necessary to obtain the desired thickness for the prefabricated panel.

The upper face of the panel is therefore superficially finished with methods known per se. After the concrete has dried sufficiently, the panel is removed from the table.

Claims (16)

R I V E N D I C AZ I O N I 1. Modular component for the construction of building structures with uniform insulation, characterized in that it comprises a main body (2) with a substantially flat development and with longitudinal end edges (5, 6), said main body (2) being provided with connection means (7, 8, 7 ', 8') arranged along said longitudinal edges for mutual coupling with adjacent similar modular components (1 ', 1 ") so as to define an insulating panel (P) that is substantially continuous and free of thermal bridges, anchoring elements (9, 10, 11, 12) being formed on said main body (2) for stable anchoring to the concrete mass (16, 16 ', 16 ") or filling material of the structure wall (M) in which the component is inserted. 2. Modular component according to claim 1, characterized in that it consists of a section of extruded thermoplastic material provided with at least one substantially flat face (3, 4) parallel to a main development plane (H). 3. Modular component according to claim 2, characterized in that said main body (2) has a substantially box-like shape with at least two flat faces (3, 4) spaced apart and substantially parallel to said main development plane (H) in so as to define at least one longitudinal cavity or compartment. 4. Modular component according to one or more of the preceding claims, characterized in that said anchoring elements (9, 10, 11, 12) consist of stiffening ribs which extend along a longitudinal direction, on planes substantially perpendicular to said plane main development (H). 5. Modular component according to claims 3 and 4, characterized in that said anchoring elements (9, 10, 11, 12) extend outwards starting from only one of the flat faces (3, 4) of said body main (2). 6. Modular component according to claim 2, characterized in that said anchoring elements (9, 10, 11, 12) extend outwards starting from both flat faces (3, 4) of said main body (2 ). 7. Modular component according to claim 4, characterized in that said stiffening ribs defining said anchoring elements (9, 10, 11, 12) are provided with lateral projections or fins (13, 14) to favor stable anchoring of the component to the mass of the filling material (16, 16 ', 16 ") of the wall structure (M). 8. Modular component according to claim 4, characterized in that said protrusions (9, 10, 11, 12) are substantially parallel to said main development plane (H) and have a substantially constant width throughout their longitudinal development. 9. Modular component according to claim 4, characterized in that said stiffening ribs (9, 10, 11, 12) are interrupted at intervals along their longitudinal development. 10. Modular component according to claim 1, characterized in that said connecting means (7, 8) comprise respectively male (8 ', 8 ") and female (7', 7") elements. 11. Modular component according to claim 10, characterized in that said connection means (7, 8) are configured in such a way as to be able to slide together in a direction substantially parallel to said longitudinal edges. 12. Modular component according to any one of the preceding claims 1 to 7, 9, 10, characterized in that an insulating material of a natural or synthetic type is inserted into the longitudinal cavity (s) (2 <1>) of said main body (2) . 13. Method for the construction of building structures with uniform insulation, comprising the following steps: a) assembly of at least one insulating panel (P) of predetermined length obtained by reciprocally coupling a plurality of modular components (1, 1 ', 1 ") according to one or more of claims 1 to 12; b) provision of a formwork comprising at least a pair of substantially parallel side walls and insertion between them of said insulating panel (P) in a substantially intermediate position; c) arrangement of any metal reinforcement elements (18) such as bars, rods or nets in the areas or areas between said insulating panel (P) and the side walls of the formwork; d) casting of concrete (17) or of another filling material in the cavities formed between said insulating panel (P) and the side walls of said formwork; e) drying of the concrete; f) dismantling of the formwork and display of the finished building structure. 14. Method for the construction of building structures with uniform insulation, comprising the following steps: a) assembly of a pair of insulating panels (Ρ ', P ") of predetermined length obtained by mutual coupling of modular components according to one or more of claims 1 to 12; b) preparation of a formwork consisting of a pair of substantially parallel side walls, in which one of said side walls consists of one of said insulating panels, and insertion of the other insulating panel of said pair in the cavity thus formed; c) arrangement of metal reinforcing elements such as bars or nets in said interspace; d) casting of the concrete in said cavity; e) drying of the concrete; f) dismantling of the formwork by detaching only the side wall other than said insulating panel. 15. Method for the construction of building structures with uniform insulation, comprising the following steps: a) assembly of a pair of insulating panels of predetermined length obtained by mutual coupling of modular components according to one or more of claims 1 to 12; b) preparation of a formwork with a pair of substantially parallel side walls constituted by said pair of insulating panels; c) arrangement of metal reinforcement elements such as bars or nets in the cavity of said formwork between said side walls; d) casting of concrete in said cavity; e) drying of the concrete. 16. Method for making prefabricated panels with uniform insulation, comprising the following steps: a) preparation of horizontal working plans; b) laying a first layer of concrete on said floors; c) arrangement of any metal reinforcement elements (18) such as bars, rods or nets, horizontally on said first layer of concrete; d) laying of a second layer of concrete; e) assembly of at least one insulating panel (P) of predetermined length obtained by reciprocally coupling a plurality of modular components (1, 1 ', 1 ") according to one or more of claims 1 to 12; f) support of! panel (P), horizontally on said second concrete layer; g) settling of the panel (P) in such a way as to immerse the ribs (9, 10, 11, 12) in the concrete to promote mutual anchoring; h) laying of a third layer of concrete, with a thickness at least equal to the height of the ribs (9, 10, 11, 12); i) arrangement of a mesh or other reinforcing elements on the surface of the third concrete layer; l) laying of a fourth layer of concrete of suitable thickness; m) surface finishing of the concrete surface; n) drying of the concrete o) removal of the panel from the top.