RU2762072C1 - Flexible multi-layer construction panel - Google Patents

Abstract

FIELD: construction industry.

SUBSTANCE: invention relates to the field of construction of frame structures using flexible multilayer construction panels and is a flexible multilayer construction panel. The panel contains two surface layers made of PVC material and a layer of heat-insulating material located between them, while the surface layers include a mesh base made of intertwined polymer threads covered with PVC on at least one side, fixing elements are located on the inner side of the surface layer, which are soldered strips of PVC material, while the layer of heat-insulating material is fixed by these elements.

EFFECT: expansion of the range of construction materials.

14 cl, 4 dwg

Description

The technical field to which the invention relates

The invention relates to the field of construction of frame structures. In more detail, the invention relates to flexible multilayer building panels (sandwich panels) and is a flexible multilayer building panel intended for use in construction when sheltering capital and non-capital structures, consisting of two layers of PVC material with filling a layer of mineral wool insulation between them.

State of the art

Modern trends require modern solutions.

The sprawl of cities and infrastructure requires the rapid and inexpensive construction of various types of buildings and structures.

Prefabricated frame structures are widespread. They are used for the construction of retail space of any area, sports pavilions such as tennis courts, ice arenas, warehouses, hangars, livestock complexes, etc.

In recent years, such structures have been actively used for the construction of temporary housing, mobile hospitals.

Pre-fabricated structures are based on multilayer building panels, the composition and thickness of which is determined by the purpose of the finished structure.

For example, a sandwich-type multilayer building panel known from the document RU 2627056, (SILKART S.P.A. (IT)), 03.08.2017, has thermal insulation properties and is used for the production of roofs and walls of buildings. The panel includes a base layer of insulating material containing a first surface and a second surface; a first reinforcing layer of metallic material bonded to the base layer along said first surface; a second reinforcing layer bonded to the base layer along said second surface, said second reinforcing layer comprising a layer made of a resin material; the base layer is located between the first and second reinforcing layers, and the above second reinforcing layer contains an additional fibrous backing layer attached to the above polymeric material layer.

The invention, known from document RU132037, (Sergey Nikolayevich Aleksandrov (RU), Alexander Aleksandrovich Shilin (RU)), 09/10/2013, is characterized by the presence of two surface layers and a central layer of extruded polystyrene foam or foam, characterized in that the surface layers are made of monolithic or laminated plastic, in which case a uniform layer of glue is applied between the surface layers and the central layer, and the surface and central layers, after applying the layer of glue, are pressed for 1 min to 24 hours by cold pressing with a pressure of 8 kg / cm ² .

All products described in this description have good thermal insulation properties and strength, which is why they are actively used in the construction industry.

However, due to the specifics of their design, multilayer panels have a number of limitations associated with their use.

For example, the impossibility of using for the manufacture of structures of a round, uneven or complex shape. The presence of metal sheets or mesh, fiberglass, rigid PVC sheets in the panel makes it difficult or impossible to bend it. Large-volume panels that do not contain metal structures are also difficult to bend. In some cases, when bending, the insulation rolls up, a gap occurs at the place where the layers are glued or welded.

An additional disadvantage is the complexity and long installation time of structures consisting of multilayer panels.

Thin multilayer products are easy to bend, but they are characterized by the impossibility or limited use in cold climates, which is associated with a low level of tightness, heat and moisture insulation, increased heat loss at the joints of the panels.

Disclosure of the essence of the invention

The solution proposed for patenting, due to its composition, is devoid of the above disadvantages and is aimed at solving the problem of their elimination.

The object of the invention is a multilayer flexible building panel containing two surface layers made of PVC material, and a layer of heat-insulating material located between them, characterized in that the surface layers made of PVC material include a mesh base made of interwoven polymer threads, coated with of at least one side of PVC, on the inner side of the surface layer there are fixing elements, also characterized in that the layer of heat-insulating material is fixed by these elements.

The technical result achieved when using the invention is its ability to repeat the outer contour of the frame of a structure of a straight, round or irregular shape without violating its strength, integrity or thermal conductivity.

Unlike the known analogs, the present solution does not provide for any attachment (using adhesives, welding, etc.) of the heat-insulating material to the PVC material. The fixing elements located on the inner surface of the surface layers do not allow the heat-insulating material to move freely inside the structure, ensuring its fixation and uniform distribution inside the panel. In this case, since the inner layer is not glued or otherwise rigidly attached to the surface layer, the use of the product when covering structures with sharp corners or material requiring stretching does not lead to tears of the thermal insulation layer.

The technical result is also an increased tightness, thermal insulation and waterproofing, structures covered with the declared panels, in comparison with structures covered with rigid panels or awning.

The technical result is also simplicity and reduced construction time of the building and improved assembly quality, since the risk of mistakes during installation is minimized.

The use of the invention in the construction of structures allows to reduce the weight of the metal structure.

The properties disclosed above are provided due to the combination of flexibility and strength in the proposed product.

The overall flexibility of the product allows corners to be bypassed up to 90 degrees or less, without loss of insulation and waterproofing.

The product is used for temporary and capital construction.

Temporary buildings include buildings for accommodating workers on a construction site, shelter for grain crops at the time of harvest, an administrative and residential complex for temporary residence of athletes, kiosks, sheds, etc.

Capital construction projects include industrial, commercial and public buildings.

The PVC material used in the proposed sandwich panel consists of a mesh base and a top layer.

The mesh base consists of interwoven polymer threads. Typically lavsan, polyester or nylon yarns are used, combinations of these can also be used, but these options are not limiting.

In a private version, the base of the fabric consists of polyester and lavsan threads.

The thickness of the thread is 100-200 tex. The thickness of the thread can be 100-120, 100-130, 100-140, 100-150, 100-160, 100-170, 100-180, 100-190 tex.

The thread thickness can be selected from 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200 tex.

The thread overlap is 6 × 6; 7 × 7; 8 × 8; 9 × 9 or 12 × 12 threads per cm ² .

Typically, the warp and weft threads are intertwined at a 90 ° angle.

Depending on the density and the weaving method of the synthetic base of PVC fabric, PVC fabric can withstand loads up to 4000 daN / 5 cm.This is an indicator of strength, expressing how many decanewtons (kilograms) a tape of material 5 cm wide can withstand.

The basis weight ranges from 200 to 1500 g / m ² .

On one or both sides of the synthetic polyester base, a layer is applied that includes polyvinyl chloride. The top layer can be made of polyvinyl chloride with the addition of a plasticizer.

The base can be coated with PVC on one or both sides.

The thickness of the PVC material layer is 0.5-2mm.

Fixing elements are located on the inner side of the surface layer.

Elements of various shapes and sizes can act as fixing elements, preventing the free movement of the layer of heat-insulating material between the surface layers.

The fixing elements are soldered PVC strips.

The strips can be soldered vertically, horizontally, at an angle. The fixing elements are vertically soldered PVC strips.

Anchoring elements can be wavy lines, geometric shapes, etc.

The number of fixing elements per square meter is from 1 to 10 running meters.

The number of fixing elements per square meter is from 1 to 4 running meters.

The fixing elements can be positioned vertically, horizontally or diagonally.

In particular, PVC material can be varnished on one or both sides. The varnish can be acrylic varnish.

If the material is coated with varnish, a layer of varnish is applied to the polyvinyl chloride.

The varnish can be one or more layers. The number of layers of varnish can be 1-4, preferably 1-2 layers.

In the invention, a multi-colored varnish can be used.

At the same time, the applied at least one layer of varnish does not lead to a loss of flexibility of both the PVC material and the panel as a whole.

One or more additional layers can be applied to PVC material on one or two sides.

The additional layer can be selected from a titanium oxide layer, a polyvinylidene fluoride varnish layer, a polytetrafluoroethylene layer, a silicone layer, a polyurethane layer.

The additional layer may include a component that provides antibacterial protection against fungi and / or mold.

The number and sequence of application of layers is determined by the characteristics of the structure to be coated, climatic conditions, weather conditions, etc.

The additional layer can be an anti-fungal or antibacterial layer.

For example, PVC coatings can contain special UV stabilizers, fungicides and microbiocides, silver ions, which protect the coating and the base from the weather, the formation of colonies of microorganisms and mold, while slowing down the aging process.

The temperature range for using PVC material can be from -50 to + 70 ° C.

The temperature range for using PVC material can be from -60 to + 70 ° C.

The layer of heat-insulating material can be made of fibrous insulation with a thickness of 20-400 mm with a thermal conductivity coefficient of up to 0.04 W / mK.

The layer of insulating material can be made of basalt insulation or fiberglass insulation.

The layer of heat-insulating material can be made of mineral wool, glass wool, polyisocyanurate foam, polyurethane foam, extruded polystyrene foam.

The density of the surface layer is .0.5-1,2 kg / m ^2.

The density of the insulating layer is 30-120 kg / m ³

The thickness of the layers and panels is determined by the task at hand, for example, climatic conditions, the purpose of the building, etc.

Panel width is 1000-40000 mm; the length of the panel is 1000-50000 mm.

The layer thickness ratio is from 1: 2: 1 to 1: 400: 1.

The layer thickness ratio is from 1: 10: 1 to 1: 100: 1.

The layer thickness ratio is from 1: 50: 1 to 1: 200: 1.

The layer thickness ratio is from 1: 100: 1 to 1: 200: 1.

The layer thickness ratio is from 1: 200: 1 to 1: 300: 1.

A sandwich panel can be manufactured by assembly or layout.

The method consists of the following steps:

- cutting of awning material;

- soldering of supporting nodes;

- laying of insulation;

- trimming the insulation (if necessary);

- preliminary assembly of a multilayer building panel;

- product sealing;

- marking;

- palletizing.

Connections of elements can be performed by hot air welding without the use of filler material or by high frequency current welding (HFC welding).

The strength of the welded seams is achieved by the required overlap of the parts to be welded from 20 to 120 mm.

Brief Description of Drawings

Rice. 1 - mesh base of PVC material.

Rice. 2 - surface layer, consisting of a mesh base, two layers of PVC and one or two layers of varnish.

Rice. 3 (a-d) manufacturing of a sandwich panel for construction.

Rice. 4 (a, b). Hangar construction (example 3).

Implementation of the invention

The examples given below do not limit the invention, but only disclose information about the options for the manufacture of multilayer building panels and the possibility of their use with the achievement of a technical result.

Example 1. Manufacturing of a panel.

The flexible sandwich awning structure is a prefabricated product.

PVC material is delivered to the production site, where it undergoes primary sorting and incoming inspection. Next, the awning material is cut to size corresponding to the design documentation.

After cutting, the diagonal support nodes are soldered, which further prevent the change in the location of the insulation in the structure. Welding of the awning is carried out using hot air devices, or HFC. After the brazing of the supporting units, an enlarged assembly of the flexible sandwich awning cloth takes place. The insulation used in the flexible sandwich is pre-cut in accordance with the design documentation and placed between the fixing elements.

Further, the final sealing of the product, marking and palletizing is carried out.

The joining of PVC fabric panels is carried out by heating the overlap with a stream of hot air supplied by special welding equipment. When welding large panels, automatic and semi-automatic devices are used. For the repair of awning fabric, as well as for small-scale work, hand tools are usually used. The welded seam must undergo quality control to identify possible defects (voids, folds).

Figure 3 (a-d) illustrates the production process of the flexible sandwich tent structure.

Example 2. Operation of the product

A pre-fabricated building was built on Sakhalin for the storage and maintenance of equipment of the Russian Emergencies Ministry.

The tent structure "Flexible Sandwich" was used with the following characteristics:

- One layer

- mineral wool insulation, 150 mm thick

- PVC material thickness: 1.2 mm.

- covering with acrylic varnish on both sides of the PVC fabric;

- length 36 m

- width 24 m

- height in the ridge 7

- thickness 150 mm

- roof pitch 12

- tensile strength 400 kg / cm ²

- thermal characteristics 0.038 W / m ° C

- strength characteristics correspond to a distributed load of 8000 kg / m ² and do not depend on the presence of a roof purlinsystem, but only on the total bearing capacity of the building frame.

Technically, the deflection of the product is not limited by the tightness conditions, since nodes of adjoining products to each other are also soldered, and the roof with walls is a completely sealed shell of the building.

At the same time, the building of the Hydrometeorological Center of rigid sandwich panels was being erected on a nearby site.

- one layer

- Sandwich panel 150 mm

- mineral wool insulation

- length 26 m

- width 24 m

- height in the ridge 6 m

- thickness 150 mm

- roof pitch 12

- tensile strength corresponds to the tensile strength of steel C255 - 2550 kg / cm ² .

- thermal characteristics 0.035-0.040 W / m ° C.

- the strength characteristics of roofing sandwich panels depend on the pitch of the support girders. At the same time, the permissible load for roofing sandwich panels with a thickness of 200 mm in a span with a run step of 1.5 meters is 600 kg / m ² .

The tightness of the locks of the roofing sandwich panels limits the maximum deflection of the product within L / 200.

The building, erected using a flexible sandwich, was completed in 1.5 months, the building of the Hydrometeorological Center - in 2.5 months.

Used metal costs were 1 to 2.

After winter operation, with wind and snow loads in the building of the Hydrometeorological Center, deformations were found in the joint seams with a violation of insulation in the area of metal fittings. Due to the use of a flexible sandwich according to the invention, which is not a rigidly fixed structure, such deformations were avoided in winter and the thermal contour was preserved at all joints of the HW canvases.

Example 3 Operation of the product

The customer was given an assignment for the construction of a warehouse. For the finished object, in particular, the following requirements are imposed.

The permissible mass of snow cover is up to 210 kg / sq. m.

The maximum permissible wind speed is up to 38 kg / sq. m.

Design temperature of operation - From -50 to +50

The structure is seismically stable

The technical characteristics of the hangar are 20.0 × 22.0 × 4.0 m and are measured along the wall to the bottom of the supporting structure.

Kit specifications:

Frame of frame and awning construction:

Systems supporting the metal frame, made in the form of a spatial structure of rigid chain links connected by kinematic pairs of the first kind.

For the manufacture of systems that support as the main material, closed-section steel profiles are used, made according to the developer's technical conditions from steel grade C235. Metal structures are covered with VL-02 soil, KhV-16 enamel.

Supporting systems are delivered to the site in full factory readiness and consist of unified assembly units (substructures), which are enlarged during installation.

Fencing structure - tent structure "Flexible sandwich" prefabricated:

- (outer layer): PVC fabric is frost-resistant, does not react with chemical materials, perfectly transmits light, is resistant to ultraviolet radiation, is not afraid of temperature extremes.

- (inner layer): frost-resistant, does not react with chemical materials, perfectly transmits light, resistant to ultraviolet radiation, is not afraid of temperature extremes. The colors of the awning are Ral 9003 (signal white). Insulation - mineral wool, thickness 50 mm. Insulation flammability group - NG.

Swing gates from the end of the structure, width 5.0 m, height 3.5 m, with a wicket (0.9 × 2.1 m) - 1 pc.

Ventilation grilles at the ends of the hangar 0.6 × 1.2 m - 2 pcs.

For the construction of the warehouse, a 50 mm thick product was used, which consists of 2 layers of PVC fabric with a density of 500 g / m ² to 1100 g / m ² with a mineral wool insulation with a density of 35 kg / m ³ to 90 kg / m ³ ( Fig. 4 (a)).

The erected object is suitable for operation at outdoor air temperatures down to -20 ° C, while the product allows maintaining temperatures up to + 10 ° C indoors (Fig. 4 (b)).

Example 4. Operation of the product.

By analogy with the above methods, an object was erected in Simferopol. Purpose of the object: hangar.

For the construction of the object, a product with a thickness of 100 mm is used, consisting of 2 layers of PVC fabric with a density of 500 g / m ² to 1100 g / m ² with a mineral wool insulation with a density of 50 kg / m ³ to 90 kg / m ³ .

This product is intended for use at outdoor temperatures down to -25 ° C, while the product can maintain temperatures up to + 15 ° C indoors.

Claims (14)

1. Multilayer flexible building panel containing two surface layers made of PVC material and a layer of heat-insulating material located between them, characterized in that the surface layers made of PVC material include a mesh base made of interwoven polymer threads, covered with of at least one side of PVC, on the inner side of the surface layer there are fixing elements, which are soldered strips of PVC material, while the layer of heat-insulating material is fixed by these elements. 2. The multilayer flexible building panel of claim. 1, wherein the mesh base consists of interwoven polymer threads, where the thread is a polyester thread, a polyester thread, a nylon thread, or combinations thereof. 3. The multilayer flexible building panel of claim 2, wherein the thread thickness is 100-200 tex. 4. The multilayer flexible building panel according to claim 1, in which the overlapping area of the threads is 6 × 6; 7 × 7; 8 × 8; 9 × 9 or 12 × 12 per cm ² . 5. A multilayer flexible building panel according to claim 1, wherein the top layer is made of PVC with the addition of a plasticizer. 6. The multilayer flexible building panel of claim 1, wherein the plasticizer is a mixture of polyvinyl chloride with additives that improve the performance of the PVC fabric. 7. The multilayer flexible building panel of claim 1, wherein the thickness of the surface layer is 1-10 mm. 8. A multilayer flexible building panel according to claim 1, wherein the layer of heat-insulating material is made of fibrous insulation with a thickness of 20-400 mm. 9. A multilayer flexible building panel according to claim 1, in which the layer of heat-insulating material is made of fibrous insulation with a thermal conductivity coefficient of up to 0.04 W / mK. 10. A multilayer flexible building panel according to claim 9, wherein the layer of heat-insulating material is made of basalt insulation or fiberglass insulation. 11. The multilayer flexible building panel of claim 10, wherein the layer of insulating material is made of mineral wool or glass wool. 12. The multilayer flexible building panel of claim 1, wherein one or more additional layers can be applied to the PVC material on one or both sides. 13. The multilayer flexible building panel of claim 1, wherein the PVC material is additionally coated with at least one layer of varnish. 14. The multilayer flexible building panel of claim 1, wherein the additional layer is selected from a titanium oxide layer, a polyvinylidene fluoride varnish layer, a polytetrafluoroethylene layer, a silicone layer, and a polyurethane layer.

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