US20080066412A1 - Prefab panel for realizing a double layer wall in buildings - Google Patents

Prefab panel for realizing a double layer wall in buildings Download PDF

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Publication number
US20080066412A1
US20080066412A1 US11/843,477 US84347707A US2008066412A1 US 20080066412 A1 US20080066412 A1 US 20080066412A1 US 84347707 A US84347707 A US 84347707A US 2008066412 A1 US2008066412 A1 US 2008066412A1
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US
United States
Prior art keywords
insulating material
panel according
prefab panel
prefab
cement mortar
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/843,477
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English (en)
Inventor
Valente FRANCO
Peccolo MAURIZIO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BIT Tech Ltd
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BIT Tech Ltd
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Filing date
Publication date
Application filed by BIT Tech Ltd filed Critical BIT Tech Ltd
Assigned to BIT TECHNOLOGIES LIMITED reassignment BIT TECHNOLOGIES LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FRANCO, VALENTE CARMINE, MAURIZIO, PECCOLO
Publication of US20080066412A1 publication Critical patent/US20080066412A1/en
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/041—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E04C1/41—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • E04B2002/0208—Non-undercut connections, e.g. tongue and groove connections of trapezoidal shape

Definitions

  • the present invention relates to a prefab panel of double layer walls in buildings to provide structural support as well as thermal insulation.
  • the prefab panel can be utilized, preferably but not exclusively, as external walls of residential homes, private or public administrative or office buildings, e.g., schools and hospitals.
  • Prefab double layer walls are known as such in the building trade.
  • the present invention refers in particular to a solution for double layer walls, as disclosed in European patent application filed Feb. 13, 2006, under the number EP-06405065, the disclosure of which is hereby expressly incorporated by reference in its entirety, and of which the present invention intends to provide a further improvement.
  • European patent application filed Feb. 13, 2006 under the number EP-06405065, the disclosure of which is hereby expressly incorporated by reference in its entirety, and of which the present invention intends to provide a further improvement.
  • EP-06405065 which is commonly assigned to the assignee of the present patent application, describes an element in brick material (a kind of brick or tile of oblong form) presenting certain specific properties rendering it suitable to be assembled into a double layer wall using an intermediate cement mortar layer in the inter-space between two elements of brick material arranged opposite each other.
  • Each element of brick material contains a plurality of longitudinally extending bores forming isolating air chambers or, if filled with insulation material or with cement mortar, improve the thermal insulation properties or the structural mechanical resistance properties of the element. Assembly of two elements of brick material to form a double layer wall is illustrated in a series of figures in EP-06405065 (e.g. the FIGS.
  • EP-06405065 describes the possibility of filling the longitudinal bores of the elements of brick material with more or less ecological insulation material, but this permits limited improvement merely of the thermal insulation properties in comparison with the improvement to be reached using the present invention, without impairing in any way the teachings of the preceding European patent EP-06405065.
  • the present invention applies the teachings of commonly owned European patent EP-06405065 concerning the basic structure of the double layer wall realized as well as the method of manufacturing thereof, and thus of realizing or utilizing in a rational and economical manner double layer walls suitable for all the applications provided and illustrated in the preceding application, but presenting much higher thermal insulation values compared with the ones provided according to the patent application referred to.
  • the present invention includes advantages that can be reached by substituting, in a prefab double layer wall construction, one of the layers of elements of brick material according to the teachings of EP-06405065 with elements of thermal insulating material, e.g., polystyrol, presenting essentially the same outline form as the elements of brick material substituted.
  • thermal insulating material e.g., polystyrol
  • these layers are not provided with longitudinal through bores for better mechanical strength.
  • This wall layer of polystyrol is intended, as recommended by the thermal insulation technology for buildings, to be used as the outer wall layer of the building in order to obtain the maximum advantage of applying double layer walls of this type.
  • the present invention relates to a prefab panel for assembling a double layer wall of a building, with structural support function and thermal insulation.
  • the panel includes at least one element of brick material having an exposed surface, a connection surface, a narrow side with a protrusion, and an opposite narrow side with a recess, an intermediate layer composed of cement mortar, at least one element of insulating material with a connection surface, an exposed surface, a narrow side with a protrusion, and an opposite narrow side with a recess.
  • the prefab panel can further provide that the connection surface of the at least one element of insulating material, is arranged facing the intermediate layer composed of cement mortar and comprises recesses or grooves, wherein a cross-section is substantially shaped as a “C” with its aperture oriented towards the layer of cement mortar.
  • the prefab panel can further provide that the cross-section of the grooves is substantially shaped as a “swallow tail” with its aperture oriented towards the layer of cement mortar.
  • the prefab panel can further provide that a thickness of the at least one element of insulating material ranges from approximately 5 to approximately 15 cm.
  • the prefab panel can further provide that at least one element of brick material contains a plurality of through bores extending over the whole length of the at least one element of brick material, each of which forms an insulating air chamber.
  • the prefab panel can further provide that a thickness of the at least one element of brick material ranges from approximately 8 to approximately 15 cm.
  • the prefab panel can further provide that a total thickness of the prefab panel ranges from approximately 25 to approximately 45 cm.
  • the prefab panel can further provide that at least one element of brick material and the at least one element of insulating material have essentially of the same dimensions of length, and width, respectively.
  • the prefab panel can further provide that a plurality of elements of brick material and a same plurality of elements of insulating material are suitably assembled, with the help of an intermediate layer composed of reinforced cement mortar to form a wall of the height corresponding to the length of the single elements of brick material and insulating material, respectively, and of the width corresponding to the width of the single elements, multiplied by the number of individual elements of brick material and insulating material in the corresponding direction, respectively, forming the wall height, and width, respectively.
  • the prefab panel can further provide that a length of the at least one element of insulating material ranges from approximately 100 to approximately 300 cm, and that the minimum density of the insulating material is approximately 20 kg/m 3 .
  • the prefab panel can further provide that at least one element of brick material is of a rectangular shape.
  • the prefab panel can further provide that a recess in the at least one element of brick material which extends over a whole length of the at least one brick material.
  • the prefab panel can further provide that at least one element after assembly of the building forms an inner wall surface of the building.
  • the prefab panel can further provide that an intermediate layer composed of cement mortar further comprises a suitable reinforcing structure of steel bars.
  • the prefab panel can further provide that at least one element of insulating material includes polystyrol.
  • the prefab panel can further provide that at least one element of insulating material is of a rectangular shape.
  • the prefab panel can further provide that a recess in the at least one element of insulating material which extends over a whole length of the at least one insulating material.
  • the prefab panel can further provide that at least one element of insulating material after assembly of the building forms the outside wail surface of the building, thereby forming a double layer wall with structural support function and thermal insulation.
  • the present invention provides a method of making prefab panel for assembling a double layer wall of a building, with structural support function and thermal insulation, including connecting at least one element of brick material having an exposed surface, a connection surface, a narrow side with a protrusion, and an opposite narrow side with a recess to an intermediate layer composed of cement mortar; and connecting at least one element of insulating material having a connection surface, an exposed surface, a narrow side with a protrusion, and an opposite narrow side with a recess to the intermediate layer.
  • the method of making a prefab panel can further include that the connection surface of the at least one element of insulating material, is arranged facing the intermediate layer composed of cement mortar and comprises recesses or grooves, wherein a cross-section is substantially shaped as a “C” with its aperture oriented towards the layer of cement mortar.
  • FIG. 1 is a cross-section of an inventive panel, the basic construction of which is the same as the one shown in the FIG. 13 of the EP-06405065, but with the difference that one of the elements of brick material according to the present invention has been substituted by an element of polystyrol;
  • FIG. 2 is an enlarged view of the element of polystyrol according to the FIG. 1 ;
  • FIG. 3 is an alternative element of polystyrol material applicable within the frame of the present invention, the outer shape of which is perfectly equal to the one of the element of brick material shown in e.g. the FIG. 13 of the EP-06405065;
  • FIG. 4 is the possibility of combining two elements of polystyrol with an intermediate layer of cement mortar to form a separating wall in a building. This possibility, however, is shown merely to underline the versatility of the manufacturing system for producing the inventive panels.
  • FIG. 1 illustrates a cross-sectional representation of a prefabricated panel according to the present invention, which generally corresponds to FIG. 13 of EP-06405065.
  • the corresponding description of the panel according to FIG. 13 of EP-06405065 thus can be generally adapted to the panel represented in FIG. 1 , and in particular to elements not shown in FIG. 1 , such as, e.g., steel reinforcement structures (formed e.g., as a cage), or the application of suitable distancing members.
  • steel reinforcement structures formed e.g., as a cage
  • suitable distancing members As these items are part of the technique of manufacturing of the panels described in EP-06405065, these details are not described in more detail here. It is to be noted that the manufacturing equipment for producing the panel according to FIG.
  • EP-06405065 can be used for producing the panel according to FIG. 1 of the present invention.
  • an element of thermal insulating material e.g., polystyrol
  • an element of brick material of rectangular form is designated 1 , presenting a lower side (i.e., exposed) surface 2 , an upper side (i.e., connecting) surface 3 , a narrow side with a protrusion 5 , and an opposite narrow side with a recess 6 extending over a whole length of element 1 (i.e., perpendicular to the page). Moreover, recess 6 is formed to receive protrusions of another element 1 .
  • This element 1 of brick material which can also contain the longitudinal through bores known from the FIG. 13 of the EP-06405065, and which, after assembly of the wall panel on the building site, is oriented in a vertical position to form the inner wall side.
  • the inner wall side is the one presenting lower thermal insulation
  • the outer wall side presents the higher thermal insulation.
  • a wall of a building can include any number of elements 1 , 1 ′ arranged side by side, of variable length and suitable to form—as shown in the EP-06405065—the various types of walls cited in that document.
  • an intermediate layer 7 of cement mortar is provided with suitable reinforcing steel bars (not shown).
  • the thickness of this intermediate layer depends on the application intended of the panel and thus can be chosen from a few centimeters to some decimeters.
  • the panel then is completed on its upper side with an element 8 of thermal insulating material, e.g., polystyrol, which is also of rectangular form that includes a lower side surface 9 , an upper side surface 10 , a narrow side 11 with a protrusion 12 , and an opposite narrow side with a recess 13 extending over a whole length of element 8 of thermal insulating material, e.g., polystyrol.
  • the element 8 of thermal insulating material, e.g., polystyrol which provides high thermal insulation capacity, is provided to form, after assembly of the panel on the building site, an outside wall surface of the building.
  • the dimensions of the length (l) and the width (m) (not indicated in the Figures, all of which show cross-sections at right angles to the length of the panel, but are indicated in the corresponding figures in EP-06405065) of the element 1 of brick material and of the element 8 of the thermal insulating material 8 , e.g., polystyrol, can be equal or can be multiples of each other (the width of the thermal insulating material being, e.g., twice, or half of, the width of the element of brick material).
  • the element 1 of brick material as well as the element 8 of the thermal insulating material, e.g., polystyrol, are provided with recesses or grooves extending longitudinally, where the recesses or grooves in the element 1 of brick material are the same as shown in the examples represented in EP-06405065, such that element 14 in the element 8 of thermal insulating material, e.g., polystyrol—located in the lower side surface 9 of the element, i.e., the surface oriented towards the intermediate layer of the cement mortar 7 presents a cross-section shaped as a “C” open towards the cement mortar 7 .
  • thermal insulating material e.g., polystyrol
  • the orientation of the grooves 14 extending longitudinally is not essential for the present invention. It is to be noted, however, that these grooves permit secure anchoring of the element 8 of thermal insulation material, e.g., polystyrol (which is typically light weight with little to no mechanical resistance properties) in the cement mortar 7 .
  • a preferred shape of the grooves 14 shown in the FIG. 1 in an exemplary embodiment, is the “swallow tail” cross-section, with the opening oriented towards the layer of cement mortar 7 . An advantage of this shape is that it can aid in the manufacturing process.
  • the thickness d of the element 8 of thermal insulating material ranges from approximately 5 cm to approximately 15 cm.
  • the element 1 of brick material contains a plurality of bores 15 , 15 ′, . . . 15 n , representing insulating air chambers, extending longitudinally through element 1 .
  • the plurality of bores 15 , 15 ′, . . . 15 n can also be filled with cement mortar (for increasing the mechanical resistance of the element 1 ), or with other thermally insulating material, as represented in EP-06405065.
  • the thickness f of the element 1 of brick material can range from approximately 8 cm to approximately 15 cm, whereas the total thickness D of the panel can ranges from approximately 25 to approximately 45 cm.
  • the length (l) of the element 8 of thermal insulating material e.g., polystyrol (not shown in the figures, but the length (l) of the element is similarly depicted in FIG. 3 of the EP-06405065), practical experience has shown that this length can range from approximately 100 to approximately 300 cm, with the minimum density of the thermal insulating material being approximately 20 kg/m 3 .
  • the element 8 of thermal insulating material, e.g., polystyrol according to FIG. 1 is shown enlarged for better visibility of the geometric details.
  • FIG. 3 an alternative embodiment depicting element 8 of thermal insulating material, e.g., polystyrol is shown, in which the grooves 14 are of the same, or of a similar, cross-sectional shape as the anchoring grooves of element 1 as shown in EP-06405065.
  • thermal insulating material e.g., polystyrol
  • the cross-section of the element 8 of the thermal insulating material, e.g., polystyrol can be the same, or similar to, the element 1 of brick material.
  • This can present several advantages in manufacture, for example, when the frame required for producing the panel remains independent of the type of element (of brick material or of thermal insulating material, e.g., polystyrol) is used, the flexibility of the plant for manufacturing the panels can be improved.
  • FIG. 4 depicts panel elements 8 of thermal insulating material, e.g., polystyrol, which builds on the teachings of EP-06405065.
  • thermal insulating material e.g., polystyrol
  • FIG. 4 depicts panel elements 8 of thermal insulating material, e.g., polystyrol, which builds on the teachings of EP-06405065.
  • panel elements of thermal insulating material e.g., polystyrol
  • d thickness
  • the panels shown in the FIG. 1 of the present invention can be produced.
  • double layer panels according to the FIG. 4 with two layers of elements 8 of thermal insulating material, e.g., polystyrol, can also be produced.
  • the present invention makes use of traditional materials, such as brick or tile material or plates of slate, and polystyrol which provides excellent insulation properties, reinforcing steel and cement mortar, but combines these materials in a unique and original manner, such that prefab wall panels of large dimensions can be obtained.
  • traditional materials such as brick or tile material or plates of slate
  • polystyrol which provides excellent insulation properties, reinforcing steel and cement mortar, but combines these materials in a unique and original manner, such that prefab wall panels of large dimensions can be obtained.
  • such a configuration can also provide increased structural strength, thermal insulation, and a more favorable finish.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
US11/843,477 2006-08-23 2007-08-22 Prefab panel for realizing a double layer wall in buildings Abandoned US20080066412A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH01343/06A CH699922B1 (it) 2006-08-23 2006-08-23 Pannello prefabbricato per costruire una parete doppia di edifici.
CH01343/06 2006-08-23

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US (1) US20080066412A1 (fr)
EP (1) EP1892350A2 (fr)
CH (1) CH699922B1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090288361A1 (en) * 2008-05-23 2009-11-26 S.A.C.M.E. Spa Structural element for the building trade, machine and method to make it
US20130008104A1 (en) * 2009-10-02 2013-01-10 Michele Caboni Building construction for making transpirable walls and floors
CN103046659A (zh) * 2013-01-17 2013-04-17 江苏华昊新能源科技股份有限公司 开槽保温隔热板及其制备方法
US20140083040A1 (en) * 2012-09-27 2014-03-27 Max Life, LLC Insulated wall panel
DE102016117228A1 (de) 2016-09-13 2018-03-15 Hans-Georg Göbbel Nichttragender Innenraum-Lochziegel, Mauerstein, Herstellungsverfahren dazu, Montagerahmenprofil, Fertigteilbauwand und Herstellungsverfahren
US9963885B2 (en) * 2012-09-27 2018-05-08 Max Life, LLC Wall panel
US20190277040A1 (en) * 2017-12-20 2019-09-12 Mark Arcarisi Masonary Panel Assembly

Families Citing this family (3)

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Publication number Priority date Publication date Assignee Title
CN102720298B (zh) * 2012-02-08 2016-03-23 六盘水恒远新型建材有限公司 带拉结件的复合自保温砌块
LU93208B1 (de) * 2016-09-13 2018-03-16 Goebbel Hans Georg Nichttragender Innenraum-Lochziegel, Mauerstein, Herstellungsverfahren dazu, Montagerahmenprofil, Fertigteilbauwand und Herstellungsverfahren
US20240200328A1 (en) 2022-12-19 2024-06-20 Carmine Franco Valente Prefabricated structural panel, manufacturing method and structural system

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6625948B2 (en) * 2001-07-02 2003-09-30 Carmine Franco Valente Element made from brick material and method for manufacturing prefabricated panels for building construction
US6796094B1 (en) * 2002-10-30 2004-09-28 Dionisie Kelemen Mortarless concrete wall system

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6625948B2 (en) * 2001-07-02 2003-09-30 Carmine Franco Valente Element made from brick material and method for manufacturing prefabricated panels for building construction
US6796094B1 (en) * 2002-10-30 2004-09-28 Dionisie Kelemen Mortarless concrete wall system

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9561605B2 (en) 2008-05-23 2017-02-07 S.A.C.M.E. Srl Structural element for the building trade, machine and method to make it
US20090288361A1 (en) * 2008-05-23 2009-11-26 S.A.C.M.E. Spa Structural element for the building trade, machine and method to make it
US8549808B2 (en) * 2008-05-23 2013-10-08 S.A.C.M.E. Spa Structural element for the building trade
US20130008104A1 (en) * 2009-10-02 2013-01-10 Michele Caboni Building construction for making transpirable walls and floors
US11725393B2 (en) 2012-09-27 2023-08-15 Ddp Specialty Electronic Materials Us, Llc Wall panel
US10415256B2 (en) 2012-09-27 2019-09-17 Max Life, LLC Wall panel
US20140083040A1 (en) * 2012-09-27 2014-03-27 Max Life, LLC Insulated wall panel
US12091864B2 (en) 2012-09-27 2024-09-17 Ddp Specialty Electronic Materials Us, Llc. Insulated wall panel
US9957722B2 (en) * 2012-09-27 2018-05-01 Max Life, LLC Insulated wall panel
US9963885B2 (en) * 2012-09-27 2018-05-08 Max Life, LLC Wall panel
US12091865B2 (en) 2012-09-27 2024-09-17 Ddp Specialty Electronic Materials Us, Llc. Insulated wall panel
US9353523B2 (en) * 2012-09-27 2016-05-31 Max Life, LLC Insulated wall panel
US10858843B2 (en) 2012-09-27 2020-12-08 Max Life, LLC Wall panel
US10858842B2 (en) 2012-09-27 2020-12-08 Max Life, LLC Wall panel
US11313134B2 (en) 2012-09-27 2022-04-26 Max Life, LLC Wall panel
US12084868B2 (en) 2012-09-27 2024-09-10 Ddp Specialty Electronic Materials Us, Llc. Insulated wall panel
US12006699B2 (en) 2012-09-27 2024-06-11 Ddp Specialty Electronic Materials Us, Llc Wall panel
CN103046659A (zh) * 2013-01-17 2013-04-17 江苏华昊新能源科技股份有限公司 开槽保温隔热板及其制备方法
DE102016117228A1 (de) 2016-09-13 2018-03-15 Hans-Georg Göbbel Nichttragender Innenraum-Lochziegel, Mauerstein, Herstellungsverfahren dazu, Montagerahmenprofil, Fertigteilbauwand und Herstellungsverfahren
US20190277040A1 (en) * 2017-12-20 2019-09-12 Mark Arcarisi Masonary Panel Assembly

Also Published As

Publication number Publication date
CH699922B1 (it) 2010-05-31
EP1892350A2 (fr) 2008-02-27

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Owner name: BIT TECHNOLOGIES LIMITED, LUXEMBOURG

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FRANCO, VALENTE CARMINE;MAURIZIO, PECCOLO;REEL/FRAME:020195/0643

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