LT6474B - Composite building plate and method for producing and using the same - Google Patents

Abstract

Composite building wall carcass can be transported over long distances due to quite insignificant weight. Then it can be immediately positioned upright in due place at the construction site, where said carcass in container-type mold is filled with concrete mixture. The casted-panel carcass is made of assembled reinforcement carcass, which is formed of reinforcement meshes and folds that lean against the formwork wall through the spacer elements on both sides of insulation-material layer. Spaces are formed between the meshes and folds that are intended to insert and support the insulation material. This way, the insulation material does not slip and does not break when inside of multi-layer panel carcass is uniformly poured with the construction mixture.

Description

Field of the Invention

The present invention relates to the field of concrete structures for prefabricated buildings, and more specifically to reinforced concrete reinforcing frames with reinforced insulation layer.

Description of the technical level

Pre-cast concrete or prefabricated concrete structures are widely used in the construction of various types of buildings. Building a home using this type of structural element has many advantages that allow you to reduce the initial cost of construction, increase the life of the structure by using relatively inexpensive, low-maintenance building elements. Wall panels of this type are usually completely prefabricated at the factory i.e. the framework is formed and filled with concrete mixture. Such a solution is only suitable for local transportation of wall elements due to their heavy weight transportation costs.

Typically, a prefabricated prefabricated building wall structural member is produced by horizontally forming a frame of metal elements that form the reinforcement mesh of the structure and the edges of the structural constraint, where the reinforcement mesh is poured into the concrete mix. After the structure has hardened, it is placed using a lifting technique and temporarily secured in its place until other elements are formed, which then completely forms the walls of the building. This type of i.e. single-layer wall elements have poor thermal insulation properties: they transfer heat well to the interior of the building in summer and easily transfer heat to the outside in winter. Elements of this type require additional building insulation work after the walls of the building are formed of this type of elements.

Multilayer concrete wall elements are also known. These include placing the insulating layer between the concrete layers. The element thus obtained has one thicker layer of concrete which is unscrewed to the inside of the building, one thinner layer which is unscrewed to the outside of the building and a thermal insulation layer between the two concrete layers. The panels manufactured in this way are heavy and therefore represent a high transport cost when manufactured at the factory. Formation of sandwich panels at the construction site is difficult and time-consuming, since the reinforcement mesh of the slab has to be formed, followed by a single layer of concrete followed by a layer of thermal insulation and finally a second layer of concrete mix. The reinforcement structure must be extremely robust and of high quality welding, since the layer of thermal insulation material placed between the concrete wall construction allows the construction of defects in the wall construction, which can affect both the strength and thermal properties of the wall.

U.S. Pat. No. 5,758,463 (A) discloses a modular concrete building board comprising a frame made of metal profiles, a layer of thermal insulation material inserted between the frame members, which is filled with a layer of concrete mixture to form a concrete layer and wherein the concrete layer is adjacent to the thermal insulation material. layer is additionally fastened using nails. The main disadvantages are that the panel does not have a common internal reinforcement frame and, at critical points near the middle frame profiles, can easily be broken during installation or during operation of the building, and high temperature transfer through the metal frame (such frost bridge can frost the wall).

U.S. Pat. No. 7,681,368 (B1) discloses a concrete composite wall panel for the construction of an exterior wall of a building. Said slab includes assembling from separate slabs of concrete and thermal insulation material, where the slabs are prefabricated and have openings for windows and doors. The insulating material layer between the concrete slabs is fastened by mechanical fastening elements to both concrete slabs. The main disadvantage of this slab is that the technology is adapted for the construction of low-rise buildings due to the thin layer of concrete and the inadequate reinforcement that can withstand the loads of other floors. Threaded parts do not allow the use of temperature-resistant reinforcing materials (eg fiberglass). Alternatively, in the case of lower-cost technology, when installing a low-rise house without formwork, the interior and exterior walls are reinforced with reinforcing mesh, sprayed with concrete and immediately sealed.

U.S. Pat. No. 8,555,584 (B2) describes a multilayer element for a raised concrete wall and a method of forming it. The method comprises pouring a first concrete layer in a horizontal position, forming a thermal insulation layer of a thermal insulation material equivalent to at least 2.7 cm polyester foam layer, and pouring a second concrete layer on said thermal insulation layer. The insulating material layer is anchored to the concrete layers by anchoring fasteners. Attaching insulation to a brick wall and installing facade cladding is the cheapest classic solution, but requires a lot of equipment (eg scaffolding, mixers, lift ...) and a team of specialists to do the job.

US 2011/0061329 (A1) describes the closest prototype of the present invention comprising two reinforced concrete slabs and a slab of thermally insulating material therebetween, wherein the corrugated metal elements passing through the insulating slab deepen into the concrete slab as they are formed by pouring liquid concrete. The main disadvantage of such a slab and its formation is that the formation of the first and second concrete layers of this slab is not intended to connect the reinforcing mesh to the mesh on the other side of the thermal insulation layer. The layers are bound together only by a concrete layer. At critical loads, concrete breaking and peeling are possible.

The present invention overcomes the aforementioned disadvantages: the reinforcing structure acts as a single frame through both outer layers of concrete, without critical edges or temperature bridges. It can withstand the required loads using the same technology and method of production. Also, in order to transport the products at minimal cost, container shapes with reinforcement and insulation frames are filled at the construction site by supplying concrete from a local manufacturer or a mobile mixer. The structure of the reinforcement frame is arranged to act as a support that prevents the insulation layer from moving from its intended place when filling the form with concrete, and as a single reinforcement frame connects the two layers of concrete. Based on the pre-calculated loads, the reinforcement frame and formwork are prepared in a container-type form. One standard shipping container type could accommodate and transport 7 three-layered panels.

The advantage of the multilayer wall panels according to the invention is that they are immediately insulated, so no additional insulation of the building is required during construction. The thermal insulation is usually made of stone wool or polystyrene foam and its thickness ranges from 50 to 200 mm. In turn, reinforced concrete gives the wall panels greater fire resistance while reducing sound transmission. Not to mention that reinforced concrete structures are durable.

The essence of the invention

The composite wall frame of the building can be transported over long distances without creating a heavy load. Subsequently, it may be erected immediately on its intended construction site in an upright position, where said frame in the form of a container would be filled with concrete mixture. The inflatable slab frame is formed by a formwork and a reinforcing frame attached to it, consisting of reinforcing nets and sinusoidal hinges, which rest on the formwork wall through the spacers on both sides of the insulation material. In this way, the insulating material elements enclosed by nets and hinges do not slide and break inside the sandwich panel frame when uniformly filling the form with concrete. The reinforcement frame is connected between the layers.

Brief description of the drawing figures

Other features and advantages of the invention are described in the detailed description of the invention with reference to the following drawings:

Fig. 1 is a cross-sectional view of a composite building slab.

Fig. 2 is a three-dimensional view of a cross-sectional segment of a composite building slab.

Before referring to the detailed description of the invention, with reference to the drawings of exemplary embodiments of the invention, it is to be noted that identical elements are denoted by the same numerals throughout the drawings.

Detailed Description of the Invention

It should be understood that many specific details are set forth to provide a full and comprehensible description of an exemplary embodiment of the invention. However, it will be apparent to one skilled in the art that the details of the embodiments of the invention do not limit the scope of the invention, which may be practiced without such specific guidance. The well-known techniques, procedures, and ingredients have not been described in detail to avoid the confusion of exemplifying embodiments of the invention.

The composite building wall panel (100) comprises a formwork (1) which is pre-cast prior to assembling the composite building wall panel (100); maintaining a plurality of insulation layer elements (8) at a distance from the first hinges (3) to support the formwork (1); a first reinforcement mesh (2), which may be a mesh formed of metal or composite material reinforcement disposed adjacent to the formwork (1) and attached to each of the plurality of first hinges (3) between said first formwork (1) and the first hinges (3); a second reinforcement mesh (5), which may be a mesh formed of reinforcing metal or composite material attached to said first hinges (3) on a side other than the first reinforcement mesh (2); second frost-resistant interlayer hinges (4) which are secured to the first reinforcing mesh (2) by forming gaps parallel to the insertion of two second interlayer hinges (4) into the insulating layer members (8); a third reinforcement mesh (6), which may be formed of a reinforcement of metal or composite material, and which is secured to the second interlayer hinges (4) and third hinges (7); a plurality of third hinges (7) for supporting the insulation layer and reinforcing the outer layer (10); insulating layer elements (8) which are inserted into the space limited by the first (3), interlayer second (4) and third hinged (7) thus preventing movement of the insulating layer elements (8) during transport of the panel (100) and filling ; fills the inner layer (9) and the outer layer (10), one of which (9) is flooded to fill a space comprising at least: first reinforcement mesh (2), second reinforcement mesh (5), first hinges (3) and a portion of the interlayer second of hinges (4). The other filler layer (10) is flooded to fill a space comprising at least: a third reinforcing mesh (6), a third hinge (7), and a portion of the interlayer second hinges (4). Said first hinges (3) are separated from the formwork (1) by the use of special spacer elements (11), which may be plastic or concrete elements, extending from the first hinges (3) to the outer plane of the inner layer (9) in contact with the formwork. 1). Said interlayer second hinges (4) and third hinges (7) from the outer plane of the outer layer (10) for contact with the formwork (T) of the next composite panel (100 ') having the same structure as the first composite panel (100). are delimited using special spacers (11), which may be plastic or concrete.

Said inner (9) and outer (10) layers are interconnected by flexible links, by which the load from the outer weight (10) of its own weight is transferred to the inner bearing layer (9).

The frame of the composite building wall panel (100) can be formed both at the construction site and at the factory. Installation begins with mounting the load-bearing reinforcing mesh (2, 5) on the plurality of first hinges (3). On the side of the formwork (1), the hinges (11) are mounted on the hinges (3) to ensure an even spacing between the first hinges (3) and the respective surface of the formwork (1). Further, interlayer second hinges (4) are attached to the second reinforcement mesh (5), through which the load from the dead weight of the outer layer (10) is transmitted to the main layer (9). Depending on the properties of the insulation layer material, the insulation layer elements (8) may be installed during or after the frame assembly. The third retaining net (6) in the outer layer (10) is fixed to the existing interlayer hinges (4). Subsequently, the third hinges (7) of the outer layer (10) are mounted on them. Further, in order to obtain the required thickness product, another formwork (T) may be added next to the plane of the outer layer (10) of the first wall panel, from which another panel (100 ') of the same composition may be formed. 100) as previously described. In this way we can obtain the product of the desired thickness and thermal properties.

After the installation of all insulated frames, which would be separated by formwork panels (1), the form is transported to the construction site, where the gaps (9, 10) are evenly filled with concrete or other suitable building mixture. The said frame (100) frame or set thereof is delivered to the construction site in a container-type form (not shown) and may be made of assemblies (with openings for windows or partitions at the required length or height, mounting the panel up and down) or standard shapes / elements , which form the walls and partitions of a building. When the building elements are sufficiently stiff, they are lifted out of the mold and installed. The amount of repetition of the plates (100) depends on the construction, etc. modeling solutions.

Although many features and advantages have been enumerated in the description of the invention, together with the structural details and features of the invention, the description is exemplary of the invention. Changes may be made to the details, in particular the shape, size and layout of the materials, without departing from the principles of the invention, in accordance with the most widely understood meanings of the terms used herein.

Claims (6)

Definition of the Invention A composite building board (100) comprising reinforcements, concrete layers and a layer of thermal insulation material, characterized in that it comprises a separate and preformed formwork (1); a plurality of first hinges (3) for maintaining the distance of the insulation layer elements (8) from the formwork (1); a first reinforcement mesh (2) disposed adjacent to the formwork (1) and attached to each of the plurality of first hinges (3) between said first formwork (1) and the first hinges (3); a second fastening net (5) attached to said first hinges (3) on the other side than the first fastening net (2); frost-resistant interlayer second hinges (4), which are attached to the first reinforcing mesh (2) by forming gaps in parallel between the two second interlayer hinges; a third reinforcement mesh (6) which is secured to the interlayer second hinges (4) and third hinges (7); a plurality of third hinges (7) for supporting the insulation layer and reinforcing the outer layer (10); insulating layer elements (8) which are inserted into a space bounded by first hinges (3), interlayer second hinges (4) and third hinges (7); fills the inner layer (9) and outer layer (10); intermediate elements (11). A composite building board (100) according to claim 1, wherein the reinforcing nets (2, 5, 6) are made of a material selected from metal or composite material reinforcement. A composite building board (100) according to claim 1, wherein the hinges (3, 4, 7) are sinusoidal. A composite building board (100) according to claim 1, wherein the filler inner layer (9) comprises a space comprising at least a first reinforcement mesh (2), a second reinforcement mesh (5), first hinges (3) and a portion of the interlayer second hinges (9). 4) and the filler outer layer (10) comprises a space comprising at least a third reinforcing mesh (6), a third hinge (7) and a portion of the interlayer second hinges (4). A method of manufacturing a composite panel (100) according to any one of the preceding claims, comprising applying a concrete mixture to reinforcing reinforcements and a thermal insulation layer, the method comprising the steps of: (a) assembling the container in an upright position to receive the article from at least one composite panel (100); b) inserting the formwork (1) into the assembled form of the container, which is pre-cast before assembling the composite wall panel (100) of the building; c) a container is provided with a reinforcing joint and mesh frame adjacent to the formwork (1), facing the formwork (1) with the inner filler (9), which is obtained by: c-i) providing each first hinge (3) with retaining members (11) for maintaining an equal distance of all hinges from the formwork (1); c-ii) attaching the first fastening net (2) to each of the plurality of first hinges (3) between said first formwork (1) and the first hinges (3); c-iii) attaching a second fastening net (5) to said first hinges (3) on the other side than the first fastening net (2); c-iv) attaching the cold-impermeable interlayer second hinges (4) to the first reinforcing mesh (2), forming gaps parallel to the insertion of two second interlayer hinges (4) into the insulating layer members (8); c-v) attaching a third reinforcement mesh (6) to the second interlayer hinges (4) and third hinges (7) for supporting the insulation layer and reinforcing the outer layer (10); c-vi) attaching special spacer elements (11) to the third hinges (7), to maintain an even space between the third hinges (7) and the inner surface of the outer layer (10); c-vii) inserting the insulating layer elements (8), which are inserted into the space limited by the first (3), interlayer second (4) and third hinges (7) during or after the frame assembly; d) filling the space of said inner layer (9) and the space of said outer layer (10) with a composite bond; e) dismantling of the container-shape with the filling of the inner layer (9) and the outer layer (10). A method of forming a composite product of a plurality of composite panels according to any one of claims 1 to 4, comprising the steps of: (aa) assembling the container in an upright position to receive a plurality of composite panels (100); bb) inserting a first formwork (1) into the assembled form of the container, which is pre-cast before assembling the composite wall panel (100) of the building; cc) inserting a reinforcing joint and mesh frame into the container adjacent to the first formwork (1), facing each of the first formwork (1) with an inner filler (9), with respect to the next formwork (T), wherein said frame is obtained in steps ci to c -vii; dd) inserting a second formwork (T) into the assembled form of the container, which is pre-cast before assembling the composite wall panel (100 ') of the building; ee) steps aa) to dd) are repeated until the required article thickness is obtained; ff) a building mixture for filling the space between each of said inner layers (9) and said outer layer (10) between all formwork; gg) disassembling the container-shaped stops of the fillings of the inner layer (9) and the outer layer (10).