JP2002535527A - Building systems - Google Patents

Abstract

(57) Summary: Adopting a honeycomb panel (as defined herein) having at least one flat edge that joins adjacent structural units, and joining the panels and / or units together to form a composite building. And a forming step. The adjacent structural unit may be another honeycomb panel, beam, corner, or other desired unit. The honeycomb panel is preferably the honeycomb panel of the applicant's EP 0 708 706. The panel can be an ideal panel and the panel can be manufactured in an open or facing panel configuration. Further, the panels can be manufactured in large dimensions, for example, 0.9 mx 2.5 m, thickness 40 mm. Panels can be modularized by assembling reinforcing fibers in a narrow (eg, 300 mm wide) panel preform. During the molding stage, three fiber preforms are loaded into a suitable mold tool to form a 900 mm wide panel. A further property of the panel is that it behaves like a beam in all directions, but is particularly effective as a beam when mounted on an edge. The structure of the panel is such that the honeycomb structure is always integrated with the continuous straight edges and is joined by the edges. By effectively securing a beam portion of the composite material, such as a flat plate or box portion, to the edge of the panel, the properties of the panel, which when functioning as a beam, can be enhanced to be a beam, if effective.

Description

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a building system, and more particularly, to a building system using a composite material.

New composite materials have the physical properties that make them ideal for the construction of many types of buildings (especially houses). The new composites are lightweight, generally less than 25% of steel, but comparable in strength to steel. The new composite material, when processed, can withstand permanent immersion in water and is not attacked by various rots or eaten by termites. When new composites are built in houses and other structures, they provide a structure that can withstand earthquakes and storms. If the fibers used in the composite are glass fibers, the raw materials are plentiful and inexpensive, and the glass is reusable. The composite material has excellent creep resistance, making it suitable for long-term load applications. The thermal properties are also excellent, reducing energy requirements and allowing renewable energy sources, such as solar energy, to be important sources of heating.

[0003] New types of composite materials are gradually finding new uses, but there has been little use in large composite structures such as buildings and houses. For example, "I
Composite structural members such as “beams”, chevrons, box beams, etc.
Manufactured by a "butt" process for many years, it has proven difficult to secure together. New composites, like metal, do not deform plastically and cannot be effectively fixed together using bolts, screws and rivets. Moreover, new composite materials cannot be welded. The lack of such an effective fastening method has severely limited the development of new composite applications, despite their excellent physical properties.

[0004] The object of the present invention is to provide a system comprising a composite structural member, which is suitable for many applications, but especially for the construction of houses or other buildings, and to effectively fuse the structural member. Another object of the present invention is to provide a single new composite structure.

[0005] In its broadest aspect, the present invention is directed to a honeycomb panel having at least one flat edge for bonding to an adjacent structural unit (Head Office first defined below)
And a method of combining panels and / or units together to form a composite building.

[0006] The adjacent structural unit may be another honeycomb panel, beam or corner, or other desired unit as described in further detail below. Analysis of a typical wall, as shown in FIG. 1 of the accompanying drawings, shows that all of this type of structure includes three basic members: panels, beams and corners. Therefore, any building system must provide three members efficiently.

[0007] Manufacturing large composite panels using conventional components requires that the flat sheet of material is not sufficiently rigid and requires many additional support structures to achieve the desired hardness of the wall panels. ,Have difficulty. This problem is addressed by the applicant's European Patent 0 708.
This was overcome by the 706 honeycomb panel. The honeycomb shape of this structure is
The panel can be an ideal panel and the panel can be manufactured in an open or facing panel configuration. Further, the panel is, for example, 0.9 m × 2.5 m and has a thickness of 40 m.
mm. The panel is made of reinforcing fibers, for example, 30
It can be modularized by incorporating it into a narrow panel preform having a width of 0 m. During the forming stage, three fiber preforms are loaded into a suitable mold tool to form a 900 mm wide panel. A further property of the panel is that it acts in all directions like a beam, but is particularly useful as a beam when a honeycomb is used at the edge of the panel, as shown in FIG. 2 of the accompanying drawings.
The structure of the panel may be such that the honeycomb structure is always integral with and joined by continuous straight edges. By effectively securing a portion of the composite beam, such as a flat plate or box portion, to the edge of the panel, the characteristics of the panel acting as a beam, if available, can be used to connect the beam to FIGS.
As shown in FIG.

[0008] The honeycomb panel thus provides two members of the wall: a panel and a beam. The problem of the third member, the corner, can be solved by using a box portion. The box portion will, of course, typically have multiple faces, or four, or three or more. In FIG. 4 of the accompanying drawings, three panels are 4
It is shown mounted on one box beam with two sides.

Thus, the box beam acts as a corner, allowing the panel to actually change direction, eg, 90 degrees. The honeycomb panels are preferably joined on all four sides by flat edges and can therefore be fixed to other panels or beam parts or combinations thereof. Thus, by combining these elements, it is possible to build complex structures and meet the requirements for panels, beams and corners.

[0010] The property of honeycomb panels is that they can be manufactured as open structures, and another construction method is to glue the inner panels with open structures, for example in hollow walls, and the exterior boards are glued directly to the panels in place. Would be used to The facing board may be plasterboard, fabric coverboard, or any desired decorative or stationary surface.

Although it has been shown that a composite structure can be formed by combining a honeycomb panel and a beam portion, a method for effectively fixing these members is required, and the honeycomb structure has a form of a bracket. The resulting structure must be examined to determine if additional structures are needed.

The advantage of the composite is that it can be very effectively glued with existing adhesives to the extent that the joint has a similar strength as the base material. Furthermore, the honeycomb panels are preferably always joined by a flat surface which can engage with the flat surface of another panel or beam part. Therefore, there is an opportunity to form an adhesive joint at the boundaries of these flat surfaces.

A properly configured joint actually “welds” the components of the system, allowing them to function as a single element. Such a joint may also be liquid tight.

According to a second aspect of the present invention, there is provided a method of joining adjacent structural units, wherein an adjacent edge of an end unit receives an adhesive spreading over an area smaller than the width of said edge. And a combination of at least one further recessed area, alone or in combination with a corresponding area of an adjacent unit, to provide an adhesive along substantially the entire adjacent surface. Providing an area on which a gallery for rapid movement can be formed.

In a preferred embodiment of the second aspect of the invention, one or both of the adjacent surfaces may be provided with a heating element for achieving rapid curing even at low temperatures. According to a third preferred embodiment of the invention, the panels and other units are manufactured from a thermoplastic resin, and a heating element can be provided for fusing adjacent surfaces by local melting of the material.

According to a fourth preferred embodiment of the present invention, there is provided a method of manufacturing a hollow wall, comprising the step of employing two or more honeycomb panels, the panels being adjacent to at least one edge of the panels. A method is provided which comprises the steps of spacing by a recess or raised area in the unit and bonding the panel to the unit.

In buildings, especially in the construction of houses, it is advantageous if the walls can be hollow. A hollow wall facilitates the invisible addition of insulation and wiring, such as wires, telephone wires and plumbing, into the wall. A hollow wall can be formed by using a honeycomb panel having an exterior surface and arranging the exterior panel so that the exterior surface faces outward. Preferably, the unit is a corner, and the corner is provided with a recess for arranging a panel.

A fifth embodiment of the present invention provides a method for forming a casement for a window, a door or the like in the hollow wall of the fourth embodiment. This method creates a hole of the desired size,
Forming panels by omitting or cutting existing panels; sealing and retaining the edges of holes by using molded strips to grip the panels; gluing the strips in place Process.

In the case of a single wall, a simpler strip surrounding the edge of the (single) panel may be used. According to a sixth embodiment of the present invention, there is provided a ferrule including a piece of material for sealing beams to beams or beams and other units. The piece of material of the ferrule is shaped to fit partially into the beam end to which the piece of material can be glued, and has an end face that can be glued to the flat surface of the beam or other unit. Have.

The invention is further described below, by way of example, with reference to the accompanying drawings, in which: With reference to these figures, FIG. 1 shows the beams 10, panels 12 and corners 14 required for a building system. Figures 2, 3 and 3a show a honeycomb panel 12 according to EP-A-0 708 706. The honeycomb panel 12 acts as a beam and actually forms an I-beam by bonding to a flat member 16 (which may itself be a honeycomb panel).

FIG. 4 shows a rectangular corner 14 to which three panels 12 are mounted. 5 and 6 show a hollow wall according to the invention. In this hollow wall, two panels 1
2 are spaced apart by beams 18 having ridges 20 for placing and supporting the panels. The two panels are then glued to beams 18 to form a wall. Beams 18 may be provided on all four sides of the wall to seal the wall, or other units may be used. In FIG. 6, the honeycomb structure 22 from which the exterior panel 24 has been cut can be seen. The panel 24 may not be present inside the wall, and the inner and outer panels may be different from each other, for example, one needs to be weatherproof and the other has a decorative finish. Will actually be different. In the structure of FIG. 5 a, “I” beam spacers 25 are used, preferably bonded to the respective inner surfaces of panel 12. The spacer 25 may be manufactured from a composite material or other suitable material such as aluminum. The spacer secures the inner surface and greatly increases the strength of the wall. This structure is used for walls that withstand very high stresses (eg walls supporting kitchen units or cupboards) or structures in areas exposed to storms.

Preferably, the honeycomb panel and the beam portion are typically a composite of glass fiber and acrylic resin. As shown in FIG. 7, a joint 26 is formed at the boundary between the panel and the beam. Joint 2 for each joined member
Six halves are provided and the joint 26 consists of a glue line 28, two shield edges 30 and a gallery 32. At appropriate locations along the joint, vents and injection holes are provided as needed. The joint 26 is manufactured as follows. Assemble the panels and beams and temporarily hold them in their respective positions with fasteners or with clamps, while simultaneously sealing all joint edges.

An adhesive, such as an adhesive of the type provided by Permabond and designated as 5002 and an acrylic resin, are injected directly into the gallery 32 of the joint 26 under pressure. Next, the resin is distributed from the gallery 32 to the glue line 28, and the air is discharged from the ventilation holes. When the resin near the vent indicates that the injection is complete, close both the vent and the nozzle hole with a small plastic plug. This type of adhesive cures sufficiently within 15 minutes at about 20 degrees that the structure is self-resisting and can be removed from fasteners or clamps that are removed when appropriate. Since the glue line 28 is continuous around the contact surface and is filled with adhesive under pressure, the joint is completely liquid tight. Therefore, structures that need to be water-retaining or water-resistant, for example roof structures, can be manufactured. The joint edge 30 is sealed by placing the gasket material on the appropriate edge prior to assembly. Permabond and Loctite provide a wide range of suitable materials.

When the assembly is performed at a low temperature, a resistive heating element 34, which is actually a very thin wire, can be incorporated into the glue line of the panel (FIG. 8). These heating elements are activated at the time of injection to ensure complete cure of the adhesive in a short time.

Although the above composites consist of glass fibers and thermosets, advances in plastics materials and the development of new fibers have made it possible to replicate components of building systems with sufficient mechanical strength. It would be possible to use a thermoplastic material as a challenge. However, thermoplastics are difficult to bond with adhesives and the above joints will not work well.
Here, another joint that enables welding of the components will be described.

In the first example, the heating element 34 is formed in the bonding surface of the honeycomb panel (or the beam) as shown in FIG. 9, or is bonded on the bonding surface. The heating element is then heated by passing a current through the heating element. When the contact surface melts, the panel and the beam are effectively pressed together to weld the panel and the beam. This method can form a good joint, but requires movement of the member. In the following, a second joint that enables fixed fastening will be described.

Here also, the heating element 34 is provided on the joining surface of the honeycomb panel 12. further,
At the center of the joint is provided a groove 36 in which a plastic piece 38 is arranged (
(FIG. 10). The plastic pieces include a heat-activatable blowing agent that expands when heated. As the joint is heated and liquefied by the heating element, the expandable plastic pieces pressurize the liquid to bring the liquid into contact with the surface of the engagement member, thereby providing a good weld joint. The heating element 34 is arranged so as not to melt the edges of the panel, thereby allowing the joint edge to hold the molten plastic in the joint. Joints of the type described can be produced in less than 5 minutes, providing a very quick assembly method.

Here, referring to FIGS. 11 to 15, the joining of beams will be considered. The box part is joined to the side of the beam, and the honeycomb panel 12 is joined to both beams (FIG. 13)
In, the panel 12 itself acts as a corner bracket and no additional bracket is required. However, if additional brackets are required due to construction or seal considerations, this can be achieved with a ferrule plug bracket (FIG. 14) that works as follows. The bracket 40 is molded into another member using a composite similar to a beam and then glued to the end of the beam portion 10 to form a butt joint as shown in FIG. The beam and honeycomb panel are then combined, while simultaneously connecting the ferrule plug bracket 40 to the adjacent beam. A preferred adhesive is again Permabond 5002. This type of bracket seals the beam-to-beam butt joint, strengthens the open end of the beam, and utilizes the available surface area within the beam to provide a very strong joint. In appearance, the bracket and the beam look like extensions of the beam, and the continuity of the connection between the beam and the honeycomb panel is maintained. An adhesive is applied to the area 42 to adhere to the inside of the beam 10, and an adhesive is applied to the area 44 to adhere to the outer surface of the corner 14.

If one beam must be joined to another length beam, the joint 46 can be made using a short length beam that only slides inside the larger main beam. (Figure 15). The joint is glued in place on one of the two beams, then the second beam is slid over the protrusion of the joint and glued in place to form a butt joint. By connecting the honeycomb panels to the beams such that they overlie the joints, the joints are further strengthened. A suitable adhesive is
Again, it would be Permabond 5002.

If simple brackets such as angle brackets are needed, these brackets can be glued or glued and screwed into the composite structure. Aluminum can also be very efficiently bonded to the composite, especially using a Permabond 5002 type acrylic adhesive. Aluminum beam sections can be used at appropriate locations on the composite beam, and this alternative may have applications.

The composite structure described above has not been directed to how to form openings for doors and windows. FIG. 16a shows a hollow wall with a partial window opening and a molded strip portion 50 providing an opening for the window. The molded strip has the cross-sectional shape shown in FIG. 16c and, as can be seen, two recesses 52 which grip each panel 12 of the hollow wall separated by spacer portions 54 for separating the panels 12. Having. The structure of the inner surface of the strip 50 is determined by a window or the like fitted into the casement opening. The assembly procedure will include gluing all components together and injecting glue into the glue lines formed in the honeycomb panel and molded strip (as in the procedure described above). The end of the molded strip portion is pre-bonded to the assembly, thereby sealing the glue line.

If a window or door opening is cut out of the honeycomb panel, this is possible using conventional equipment and diamond cutters, exposing the edges of the honeycomb and making glue line joints useless (see FIG. 16b). By using the same molded strip, it is possible to achieve a good joint by applying the adhesive to all surfaces that come into contact with the panel part. This joint need not be continuous. The strip is designed to surround each panel, thereby joining the two panels and maintaining a high degree of structural integrity. The window and the door frame can be directly attached to the opening of the casement window thus formed.

Although the panels of the present invention have been described in terms of walls, it will be appreciated that they can be used in any building or building end use, such as floor panels, roof panels, and the like.

The present invention relates to a building which can mainly use factory preformed parts, is very resistant to immersion, effectively has an integral monocoque structure, and is antiseptic and insect-proof. Provide a building system that can be constructed quickly and inexpensively.

[Brief description of the drawings]

FIG. 1 is a perspective view of two walls of a building.

FIG. 2 shows a honeycomb panel or beam.

FIG. 3 is an evolution of FIG.

FIG. 3a is an evolution of FIG.

FIG. 4 shows a panel mounted on a rectangular beam.

FIG. 5 shows a hollow wall according to the invention.

FIG. 5a shows a hollow wall according to the invention.

FIG. 6 shows a hollow wall according to the invention.

FIG. 7 shows a joining method according to the invention.

FIG. 8 shows a joining method according to the invention.

FIG. 9 shows welding of a thermoplastic unit.

FIG. 10 shows welding of a thermoplastic unit.

FIG. 11 shows the joining of beams.

FIG. 12 shows the joining of beams.

FIG. 13 shows the joining of beams.

FIG. 14 shows the joining of beams.

FIG. 15 shows the joining of beams.

16a-c show the formation of a fenestration for a window or the like.

──────────────────────────────────────────────────続 き Continuation of front page (81) Designated country EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE ), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SL, SZ, TZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CR, CU, CZ, DE, DK, DM, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID , IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, TZ, UA, UG, US, UZ, VN, YU, ZA, ZW The honeycomb structure is always integrated with the straight edge, and is connected by the edge. By effectively securing a beam of composite material, such as a flat plate or box section, to the edge of the panel, the properties of the panel acting as a beam, if effective, can be enhanced to be a beam. it can.

Claims (15)

[Claims] 1. A method comprising: employing a honeycomb panel having at least one flat edge for bonding to adjacent structural units; and joining the panels and / or units together to form a composite structure. Building method. 2. The method according to claim 1, wherein the adjacent structural unit is another honeycomb panel, beam or corner. 3. The honeycomb structure is obtained by injecting a plastic material resin into a continuous fiber network arranged in a mold so that the honeycomb structure is formed without the nets intersecting with each other. 3. The method according to 2. 4. The method according to claim 1, wherein the structure of the panel is such that the honeycomb structure is always integrated with and joined by the continuous straight edges. . 5. The method of claim 4, wherein the panel is strengthened into a beam by effectively securing a composite beam portion, such as a flat plate or box portion, to an edge of the panel. 6. The method according to claim 1, wherein the third element, the corner, is provided by the use of a box part. 7. The honeycomb panel according to claim 1, wherein the honeycomb panels are joined by flat edges, preferably on all four sides, and thus can be fixed to other panels or beam parts or a combination thereof. 7. The method according to claim 6. 8. The honeycomb panel according to claim 1, wherein the honeycomb panel is manufactured as an open structure used for a hollow wall, and the exterior board is directly bonded to the honeycomb panel in situ.
The method according to any one of claims 1 to 7. 9. A method of joining adjacent structural units, wherein the adjacent edge of the end unit has a slightly recessed area capable of receiving an adhesive spreading over an area smaller than the width of said edge; At least one more highly recessed area, by itself or in combination with a corresponding area of an adjacent unit, for rapid movement of the adhesive along substantially the entirety of the adjacent surface; Providing an area in which a gallery can be formed. 10. The method of claim 9, wherein one or both of the adjacent surfaces is provided with a heating element to achieve rapid curing even at low temperatures. 11. The panel according to claim 1, wherein the panels and other units are made of a thermoplastic resin, and a heating element is provided for fusing adjacent surfaces by local melting of the material. the method of. 12. A method of manufacturing a hollow wall, comprising employing two or more honeycomb panels and spacing the panels by a recess or raised area in a unit adjacent at least one edge of the panels. And adhering the panel to the unit. 13. A method of forming a fenestration for a window, a door or the like in a hollow wall according to claim 12, wherein a hole of a desired size is omitted, or a panel is omitted. A method comprising forming by cutting, sealing and retaining the edges of the holes by using a molded strip that grips the panel, and gluing the strip in place. 14. The method of claim 13, wherein in the case of a single-plate wall, a simpler strip surrounding the edge of the single panel may be used. 15. A ferrule for sealing a beam to a beam or a beam to another unit, the ferrule including a piece of material, wherein the material piece is partially embedded in a beam end to which the material piece can be adhered. A ferrule shaped to mate and having an end face capable of bonding to a flat surface of a beam or other unit.