US20110185664A1

US20110185664A1 - Assembly unit for building and method for fabricating and using the same

Info

Publication number: US20110185664A1
Application number: US12/279,983
Authority: US
Inventors: Kwi-Bok Lee; Kwi-Yeon Lee
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-03-30
Filing date: 2008-03-27
Publication date: 2011-08-04
Also published as: CA2639035A1; KR100771248B1; WO2008120898A1

Abstract

An assembly unit for buildings and its fabrication method are disclosed. The assembly unit includes an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, inserted in the expanded synthetic resin, a certain length of the bent portions being exposed from front and rear surfaces of the expanded synthetic resin; and a metal wire mesh mounted on the front and rear surfaces of the expanded synthetic resin and combined with the bent portions of the metal wire, to thereby obtain the working stability, so that an operator may carry it easily, shorten construction time by removing the necessity of a series of works of making a concrete form, casting concrete and curing the concreted surface, improve surroundings, and reduce construction expenses, by simply using the expanded synthetic resin, the metal wire and the metal wire mesh, compared with those of when existing reinforced concrete structures are employed.

Description

TECHNICAL FIELD

The present invention relates to construction technology. More particularly, this invention relates to an assembly unit for buildings that is configured to include: an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, which is inserted into the expanded synthetic resin, where a certain length of the bent portions is exposed from front and rear surfaces of the expanded synthetic resin; and a metal wire mesh mounted on the front and rear surfaces of the expanded synthetic resin and combined with the bent portions of the metal wire, to thereby secure working stability, so that an operator may carry it easily, shorten construction time by removing the necessity of a series of works of making a concrete form, casting concrete, and curing the concreted surface, improve surroundings, and reduce construction expenses, by simply using the expanded synthetic resin, the metal wire and the metal wire mesh, compared with those of when existing reinforced concrete structures are employed. Also, the present invention relates to the fabrication method of the assembly unit.

BACKGROUND ART

In general, buildings have been primarily constructed according to a reinforced concrete method. That is, the reinforced concrete structures are constructed as follows. Reinforced concrete frameworks are built to withstand the load of entire structures with pillars, beams, and slab formed by installing a concrete form starting from the lowermost floor, disposing reinforcing bars, casting concrete and curing the concreted surface, and releasing the form. Bricklaying is performed so as to be connected the reinforced concrete frameworks, and then, wall bodies are installed by using finishing materials such as mortar.
In more detail, first, the ground is dug and cast to form an underground floor, the reinforcing bars are disposed on the slab of the underground floor, and then wall body/pillar forms are installed.
Thereafter, slab/beam forms are installed at an upper portion of the wall body/pillar forms, and then, reinforcing bars are arranged in the slab/beam forms and connected to the reinforcing bars arranged in the wall body/pillar forms.
Next, concrete supplied by a concrete mixer is cast in the wall body/pillar/slab/beam forms and cured.
Through such processes, wall bodies, pillars, slab and beams are formed and a basic structure corresponding to a first floor of a building can be completed.
Thereafter, the forms are removed from the completed wall bodies, pillars, slab, and beams.
By repeatedly performing the processes, a multi-floor structure can be completed.
However, the conventional building construction method in which the wall body/pillar forms are installed, on which the slab/beam forms are then installed, the reinforcing bars in the wall body/pillar forms and those in the slab/beam forms are connected, the concrete is cast, and then the concrete surface is cured, causes many problems. This is, because the intensity work is high, worker absenteeism is also high and thus labor costs increase. In addition, the required lengthy construction time results in degradation of surrounding area, possibly including natural areas. In addition, construction expenses increase because of the use of the frameworks of the building, namely, the reinforcing bars and the concrete.
Thus, recently, in an effort to address these problems, a constructing method using a pre-cast concrete structure has come into use.
The pre-cast concrete constructing method is a technique for previously creating structures in a factory with pre-cast concrete block facilities and transferring the created structures to a construction site and successively assembling them. This method obtains quality stability, improvement of construction characteristics, standardization, and improvement of working conditions at the construction site.
However, although the pre-cast technique is aimed to partially construct structures, it has a problem in that since the structures are large, it is not easy to transport the structures from the factory to the construction site. In addition, a large crane is required for construction but such a crane cannot be used in alleys or in a high density downtown area, hindering construction.

DISCLOSURE

Technical Problem

The present invention solves the above problems, and provides an assembly unit for buildings and its fabrication method that can shorten the construction duration by omitting a series of works of making a concrete form, cast concrete, and cure the concreted surface, etc.
The present invention further provides an assembly unit for buildings and its fabrication method that can facilitate transportation of frame panels during operations by reducing the weight of the frame panels.
The present invention further provides an assembly unit for buildings and its fabrication method that can accomplish good sound-proofing without having a soundproofing device by filling the interior of a frame panel with an expanded synthetic resin.

Technical Solution

In accordance with an exemplary embodiment of the present invention, the present invention provides an assembly unit for buildings, including an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, which is inserted into the expanded synthetic resin, where a certain length of the bent portions is exposed from both front and rear surfaces of the expanded synthetic resin; and a metal wire mesh covering both front and rear surfaces of the expanded synthetic resin and fixedly combined with the bent portions of the metal wire.
Here, a first mixture, which has been composed by adding 6˜13 wt % of SiO₂, 0.1˜0.8 wt % of Al₂O₃, 0.01˜0.08 wt % of Fe₂O₃, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K₂O, 0.005˜0.05 wt % of TiO₂, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO₃to 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, is first coats both the front and rear surfaces or one of the front and rear surfaces of the expanded synthetic resin and on the surface of the metal wire mesh. A second mixture, which has been composed by adding 10˜20 wt % of SiO₂, 0.3˜0.9 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K₂O, 0.005˜0.06 wt % of TiO₂, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na₂O, 0.001˜0.007 wt % of ZrO₂, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO₃to 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, secondly coats the first coating. In addition, a third mixture, which has been composed by adding 17˜25 wt % of SiO₂, 0.2˜0.15 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K₂O, 0.01˜0.07 wt % of TiO₂, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO₃to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, thirdly coats the second coating.
In accordance with another exemplary embodiment of the present invention, the present invention provides a method for fabricating an assembly unit for buildings, including: forming bent portions by bending a metal wire in a zigzag manner (S100); fixing the bent metal wire within a mold for shaping an expanded synthetic resin (S200); injecting a synthetic resin and a foaming agent into the mold such that a certain length of the bent portions of the metal wire are exposed from front and rear surfaces of the expanded synthetic resin to thus mold the expanded synthetic resin (S300); positioning a metal wire mesh on both front and rear surfaces of the expanded synthetic resin (S400); and welding the bent portions of the metal wire and the metal wire mesh to fix the metal wire mesh on both front and rear surfaces of the expanded synthetic resin (S500).

Advantageous Effects

As described above, the assembly unit for buildings and the fabrication method according to the present invention has the following advantages.
First, since the panel for buildings is light, a worker can easily carry it, and thus, a working stability can be secured.
Second, since a series of works of fabricating a concrete form, casting concrete, and curing concreted surface are not required, the construction duration can be considerably shortened, and accordingly, the surrounding environment is not degraded.
Third, since the frame panel includes the expanded synthetic resin, the metal wire, and the metal wire mesh, the construction expenses can be reduced, compared with the conventional reinforced concrete structure.
Fourth, when the frame panel filled with the expanded synthetic resin is applied to a building, good soundproofing can be obtained without installing additional soundproofing devices.

DESCRIPTION OF DRAWINGS

The features and advantages of the present invention will be more apparent from the following detailed description in conjunction with the accompanying drawings, in which:

FIG. 1A is an exploded perspective view showing elements constituting a flat panel type assembly unit as an example of an assembly unit for buildings according to an embodiment of the present invention;

FIG. 1B is a perspective view showing a combined state of the elements according to FIG. 1A;

FIG. 1C is a side view showing an internal structure of the assembly unit combined according to FIG. 1B;

FIG. 1D is a side view showing one example of a sectional structure of the assembly unit for buildings according to FIG. 1A;

FIG. 1E is a side view showing another example of a sectional structure of the assembly unit for buildings according to FIG. 1A;

FIG. 2 is a side view showing an internal structure of an arch type assembly unit formed by shaping the expanded synthetic resin in an arch form as another example of an assembly unit for buildings according to an embodiment of the present invention;

FIG. 3A is a perspective view of a panel for a construction use formed by assembling assembly units as shown in FIG. 1 according to another embodiment of the present invention;

FIG. 3B is a perspective view showing a panel for a construction use formed by assembling assembly units as shown in FIG. 2 according to still another embodiment of the present invention;

FIG. 4A is a perspective view showing an internal structure of a rectangular pillar, one type of building pillars, formed by using the assembly unit for buildings in FIG. 1;

FIG. 4B is a perspective view showing an internal structure of a circular pillar, another type of building pillars, formed by using the assembly unit for buildings in FIG. 2;

FIG. 5 is a sectional view showing a complete form of the building pillar in FIG. 4; and

FIG. 6 is a flow chart illustrating the process of fabricating the assembly unit for buildings according to an embodiment of the present invention.

BRIEF DESCRIPTION OF SYMBOLS IN THE DRAWINGS

- 100: flat panel type assembly unit
- 110: expanded synthetic resin
- 120: metal wire
- 121: bent portion
- 130: metal wire mesh
- 140: mold

BEST MODE

The assembly unit for buildings and its fabrication method according to an exemplary embodiment of the present invention will now be described with reference to the accompanying drawings.
In brief, FIGS. 1A to 1E show a flat panel type assembly unit as an example of an assembly unit for buildings according to an embodiment of the present invention. Specifically, FIG. 1A is an exploded perspective view of each element constituting the flat panel type assembly unit, FIG. 1B shows a combined state of the elements in FIG. 1A, FIG. 1C is a side view showing an internal structure of the assembly unit as combined in FIG. 1B, FIG. 1A shows one example of a sectional construction of the assembly unit for buildings in FIG. 1A, where one surface is coated and cement layers are discriminated, and FIG. 1E shows another example of a sectional construction of the assembly unit for buildings in FIG. 1A, where both surfaces are coated and cement layers are discriminated.
As shown in the drawings, a flat panel type assembly unit 100 is provided in a state that a plurality of metal wires 120 are insertedly positioned in the interior of an expanded synthetic resin 110 along a lengthwise direction of the expanded synthetic resin 110. Each metal wire 120 is bent in a zigzag manner (See FIG. 1C), forming bent portions 121. A certain height of the bent portions 121 are protruded from front and rear surfaces of the expanded synthetic resin 110.
The assembly unit for buildings may be formed by using a single expanded synthetic resin or a plurality of expanded synthetic resins. FIG. 1A to 1 e show the process of constructing the assembly unit for buildings by using a plurality of expanded synthetic resins 110.
With reference to FIG. 1A, a plurality of expanded synthetic resins 110 are arranged side by side. Metal wire mesh 130 are positioned to cover the front and rear surfaces of the arranged expanded synthetic resins 110, and then fixedly combined to the bent portions 121 of the metal wire 120 protruded from both surfaces of the expanded synthetic resins 110.
In this case, as shown in FIGS. 1B and 1C, the metal wire mesh 130 are separated by a certain space from the expanded synthetic resins 110 and welded to ends of the bent portions 121 of the metal wire 120.
The assembly unit 100 for buildings may be provided with a different size according to requirements at a construction site, and such single units as shown in FIG. 1B may be connected so as to be provided as a panel type as shown in FIG. 3A (to be described).
The expanded synthetic resins 110 may be made of one selected from the group consisting of flame-resistant expandable polystyrene (ESP), self-extinguishable expandable polystyrene and expandable polypropylene (EPP).
The flame-resistant expandable polystyrene is obtained by adding 5˜10 wt % of isopentane as a foaming agent and 10˜15 wt % of magnesium hydroxide (Mg(OH)₂) as a flame retardant to 75˜85 wt % of polystyrene.
When polystyrene used is less than 75 wt %, durability would be degraded, and when polystyrene used is more than 85 wt %, expandability and flame retardancy would be degraded. Thus, polystyrene used should preferably be within the range of about 75˜85 wt %.
When isopentane used is less than 5 wt %, expandability would be degraded, but when more than 10 wt %, durability and flame retardancy would be degraded. Thus, isopentane used should preferably be within the range of about 5˜10 wt %.
When magnesium hydroxide (Mg(OH)₂) used is less than 10 wt %, flame retardancy would be degraded, while when it is more than 15 wt %, durability and expandability would be degraded. Thus, magnesium hydroxide used should preferably be within the range of about 10˜15 wt %.
The self-extinguishable expandable polystyrene is obtained by adding 6˜15 wt % of isopentane as a foaming agent and 4˜5 wt % of carbon dioxide (CO₂) to 80˜90 wt % of polystyrene.
When polystyrene used is less than 80 wt %, durability would be degraded, and when polystyrene used is more than 90 wt %, expandability and self-extinguishability would be degraded. Thus, polystyrene is preferably used within the range of about 80˜90 wt %.
When isopentane used is by less than 5 wt %, expandability would be degraded, while when it is more than 10 wt %, durability and self-extinguishability would be degraded. Thus, isopentane used should preferably be within the range of about 5˜10 wt %.
When carbon dioxide (CO₂) used is less than 4 wt %, self-extinguishability would be degraded, while when it is more than 5 wt %, durability and expandability would be degraded. Thus, carbon dioxide used should preferably be within the range of about 4˜5 wt %.
The expandable polypropylene is obtained by adding 8˜12 wt % of isopentane as a foaming agent to 88˜92 wt % of polypropylene having a melting point (Tm) of 162.65° C. and density of 0.90 g/cm³.
When polypropylene used is less than 88 wt %, durability of expandable polypropylene would be degraded, and when it is more than 92 wt %, foaming does not occur well. Thus, polypropylene used should preferably be within the range of 88˜92 wt % with respect to the foaming agent.
Isopentane is used in connection with a mixture rate of polypropylene. When isopentane used is less than 8 wt %, expandability would be degraded, and when it is more than 12 wt %, durability of expandable polypropylene would be degraded. Thus, the foaming agent used should preferably be within the range of about 88˜92 wt %.
As shown in FIGS. 1D and 1E, both or one surface of the expanded synthetic resin 110 of the assembly unit 100 for buildings may be coated with a covering material and accordingly provided. As the covering material for the assembly unit, a certain mixed material including a cement component is preferably used.
As for the assembly unit 100 for buildings according to the present invention as shown in FIG. 1D, the front and rear surfaces of the assembly unit 100 having such a form as shown in FIGS. 1B and 1C are coated with a cement mixture and surface-treated, and then formed to be a suitable size for a given construction site. As for the assembly unit for buildings 100 as shown in FIG. 1E, only one surface thereof is coated with the cement mixture and the other surface, on which the cement mixture is not coated, is in a state that the bent portions 121 of the metal wire 120 are exposed. The other surface with the bent portions exposed may be surface-treated with a cement mixture as required for a given construction site.
The composition of components in the respective surface-treated layers, as shown in FIGS. 1D and 1E, is described.
A surface-treated first layer 141 is formed by coating a first mixture, which has been prepared by adding 6˜13 wt % of SiO₂, 0.1˜0.8 wt % of Al₂O₃, 0.01˜0.08 wt % of Fe₂O₃, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K₂O, 0.005˜0.05 wt % of TiO₂, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO₃to 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, on the surface of the expanded synthetic resin 110 and also on the surface of the metal wire mesh 130.
A surface-treated second layer 142 is formed by coating a second mixture, which has been prepared by adding 10˜20 wt % of SiO₂, 0.3˜0.9 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K₂O, 0.005˜0.06 wt % of TiO₂, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na₂O, 0.001˜0.007 wt % of ZrO₂, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO₃to 66.218˜84.557 wt % of silica sand of 0.1 mm˜1.5 mm, on the first layer 141.
A surface-treated third layer 143 is formed by coating a third mixture, which has been prepared by adding 17˜25 wt % of SiO₂, 0.2˜0.15 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K₂O, 0.01˜0.07 wt % of TiO₂, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO₃to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, on the second layer 142.
FIG. 2 is a side view showing the internal structure of an arch type assembly unit formed by shaping the expanded synthetic resin in an arch form, another example of an assembly unit for buildings according to an embodiment of the present invention.
In detail, an arch type assembly unit 100′ is provided with one or more metal wires 120 bent in a zigzag manner and insertedly positioned within the expanded synthetic resin 110.
A certain height of the bent portions 121 of the metal wires 120 protrudes from front and rear surfaces of the expanded synthetic resin 110. Arch type metal wire mesh 130, corresponding to the area of the expanded synthetic resin 110, are welded and fixed to ends of the protruded bent portions 121 of the metal wires 120 in such a state that the arch type metal wire mesh 130 are separated by a certain interval from the front and rear surfaces of the expanded synthetic resin 110 with the protruded bent portions 121.
The arch type assembly unit 100′ may be formed by using a plurality of expanded synthetic resins 110 each having the bent metal wire 120, and in this case, the expanded synthetic resins 110 can be arranged side by side and assembled.
The arch type assembly unit 100′ may be used for the arch type structure of a building's door, window, ceiling, etc.
FIGS. 3A and 3B show usage examples of the assembly unit for buildings according to the embodiment of the present invention. Specifically, FIG. 3A shows a panel of a certain size for building construction that is formed by assembling flat plate type assembly units 100 according to in FIG. 1, and FIG. 3B shows a panel of a certain size for building construction that is formed by assembling arch type assembly units 100′ according to FIG. 2.
The flat panel as shown in FIG. 3A can be fabricated as a desired size by combining ends of the metal wire mesh 130 of the plurality of flat plate type assembly units 100 through welding. Also, the arch type panel as shown in FIG. 3B can be fabricated with a desired size by combining ends of the metal wire mesh 130 of the plurality arch type assembly units 100′ through welding as shown in FIG. 3B.
The assembly unit for buildings according to the present invention can be also fabricated as a structure such as a pillar or a beam in addition to the panels as shown in FIG. 3. In the case of constructing a pillar or a beam, a steel frame is installed and the assembly units according to the present invention may be assembled and connected at an outer side thereof in order to enhance structural stability.
FIG. 4A shows an internal structure of a rectangular pillar formed by using the assembly unit for buildings in FIG. 1, FIG. 4B shows an internal structure of a circular pillar formed by using the assembly unit for buildings in FIG. 2, and FIG. 5 is a sectional view showing a complete form of the building pillar in FIG. 4.
As shown in FIG. 4A, a rectangular pillar 200 is formed such that a plurality of expanded synthetic resins 210, having the metal wires 220 bent in a zigzag manner, are arranged side by side and the metal wire mesh 230 are welded and fixed to the bent portions 221 of the metal wire protruded from the front and rear surfaces of the expanded synthetic resin 210.
In this case, an iron beam may be introduced into the combined rectangular pillar 200 to enhance the strength, and in this case, an insertion hole 250 for inserting the iron beam vertically is formed at the center of the expanded synthetic resin 210 and an H-shaped beam (F) as shown in FIG. 4A may be inserted into the insertion hole 250.
Thereafter, cement mixture layers 241 to 243 as described in FIG. 1D or 1E are formed by stages on one surface or on the entire surface of the rectangular pillar 200 to complete the surface-treated rectangular pillar 200 as shown in FIG. 5.
A circular pillar 200′ as shown in FIG. 4B is formed such that a plurality of expanded synthetic resins 210 having the metal wires (not shown) bent in a zigzag manner are arranged side by side and the metal wire mesh 230 surrounding the circumference of the expanded synthetic resins 210 are welded and fixed to the bent portions 221 of the metal wire protruded from the front and rear surfaces of the expanded synthetic resin 210.
In this case, an iron beam may be introduced into the combined circular pillar 200′ to enhance the strength, and in this case, an insertion hole 250 for inserting the iron beam vertically is formed at the center of the expanded synthetic resin 210 and an H-shaped beam (F) as shown in FIG. 4B may be inserted into the insertion hole 250.
Thereafter, cement mixture layers 241 to 243 as described in FIG. 1D or 1E are formed by stages on the circumferential surface of the circular pillar 200′ to complete the surface-treated circular pillar 200′ as shown in FIG. 5.
In the present invention, preferably, as a material of the metal wires 120 and 220 and the metal wire mesh 130 and 230, soft steel obtained by adding 0.12˜0.25% of carbon to iron used as steel of a general steel frame structure that has high strength and can withstand considerable deformation and damage, may be used to reduce the risk of brittle failure that occurs when iron is suddenly damaged by a slight deformation due to an external force.
A method for fabricating the assembly unit for buildings according to an embodiment of the present invention is described.
FIG. 6 is a flow chart illustrating the process of fabricating the assembly unit for building according to an embodiment of the present invention.
In order to fabricate the assembly unit for buildings according to an embodiment of the present invention, first, a metal wire 120 of a certain length as shown in FIG. 4A is bent in a zigzag manner to obtain bent portions 121 (S100). The bent metal wire 120 is fixed in a mold to shape an expanded synthetic resin (S200). A synthetic resin and a foaming agent are injected into the mold to shape the expanded synthetic resin 110 (S300) (See FIG. 4B).
In the state that the metal wire 120 is fixed within the mold, the expanded synthetic resin 110 is molded to integrate the expanded synthetic resin 110 and the internally bent metal wire 120. In this case, the expanded synthetic resin 110 is molded such that a certain length of the bent portions 121 of the metal wire 120 are exposed from the front and rear surfaces of the expanded synthetic resin 110.
When a single metal wire 120 is inserted in the expanded synthetic resin 110 in order to fabricate the afore-mentioned arch type frame panel, a plurality of expanded synthetic resins 110 each including the metal wire 120 is prepared by performing the process as described above and placed side by side in a lengthwise direction. And then, the sides of the plurality of expanded synthetic resins 110 are attached to integrate the expanded synthetic resins 110 (S350).
Next, the metal wire mesh 130, which are the same size as the area of the front and rear surfaces of the expanded synthetic resin 110, are formed (S400), and then mounted on the front and rear surfaces of the expanded synthetic resin 110 (S500).
In this case, the metal wire meshes 130 are formed by welding metal wire horizontally and vertically in a checkered pattern.
In mounting the metal wire meshes 130 to the front and rear surfaces of the expanded synthetic resin 110, as described above, the bent portions 121 of the metal wire 120 exposed from the front and rear surfaces of the expanded synthetic resin 110 and portions of the metal wire meshes 130 are weld to combine the integrated expanded synthetic resin 110 and the metal wire mesh 130.
A method for treating the surface of the assembly unit for buildings according to an embodiment of the present invention is described.
After forming a certain structure by assembling the assembly units for buildings fabricated as described above, a first mixture, which has been prepared by adding 6˜13 wt % of SiO₂, 0.1˜0.8 wt % of Al₂O₃, 0.01˜0.08 wt % of Fe₂O₃, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K₂O, 0.005˜0.05 wt % of TiO₂, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO₃to 75.366˜90.722 wt % of silica sand of 0.1˜1.5 mm, first coats the both or one of the front and rear surfaces of the expanded synthetic resin and also on the surface of the metal wire mesh and then is cured, for a surface treatment.
After curing the first coating, a second mixture, which has been prepared by adding 10˜20 wt % of SiO₂, 0.3˜0.9 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K₂O, 0.005˜0.06 wt % of TiO₂, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na₂O, 0.001˜0.007 wt % of ZrO₂, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO₃to 66.21˜884.557 wt % of silica sand of 0.1˜1.5 mm, secondly coats the cured first coating (s), and is then cured.
After curing the second coated surface, a third mixture, which has been prepared by adding 17˜25 wt % of SiO₂, 0.2˜0.15 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K₂O, 0.01˜0.07 wt % of TiO₂, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO₃to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, thirdly coats the cured secondly coating, and is then cured.
The substantial mixture ratios with respect to the first to third coatings of the mixtures will now be described through embodiments.

Embodiment 1

First Coat

A mixture obtained by adding 6 kg of SiO₂, 0.1 kg of Al₂O₃, 0.01 kg of Fe₂O₃, 3 kg of CaO, 0.005 kg of K₂O, 0.005 kg of TiO₂, 0.05 kg of MgO, 0.001 kg of MnO, 0.005 kg of Na₂O, 0.001 kg of ZrO₂, 0.001 kg of SrO, and 0.05 kg of SO₃to 90.772 kg of silica sand of 0.5 mm is used for the first coat.

Embodiment 2

Second Coat

A mixture obtained by adding 10 Kg of SiO₂, 0.3 kg of Al₂O₃, 0.01 kg of Fe₂O₃, 5 kg of CaO, 0.005 kg of K₂O, 0.005 kg of TiO₂, 0.1 kg of MgO, 0.001 kg of MnO, 0.01 kg of Na₂O, 0.001 kg of ZrO₂, 0.001 kg of SrO, and 0.01 kg of SO₃to 84.557 kg of silica sand of 1.0 mm is used for the second coat.

Embodiment 3

Third Coat

A mixture obtained by adding 17 kg of SiO₂, 0.2 kg of Al₂O₃, 0.01 kg of Fe₂O₃, 8 kg of CaO, 0.01 kg of K₂O, 0.01 kg of TiO₂, 0.1 kg of MgO, 0.001 kg of MnO, 0.01 kg of Na₂O, 0.001 kg of ZrO₂, 0.001 kg of SrO, and 0.1 kg of SO₃to 74.557 kg of silica sand of 1.5 mm is used for the third coat.
The operational effects of the assembly unit for buildings according to the present invention will now be described in detail.
The assembly unit 100 fabricated through the above-described processes can replace the existing the reinforced concrete structures. First, a foundation work (ground concrete work) for a construction work is performed; that is, the foundation is dug, and a basic concrete basement floor is cast. Thereafter, the frame panels are welded and combined to form the structure of the inner and outer walls of the building.
That is, the frame panels including the plurality of expanded synthetic resins 110 are combined by welding the metal wires 120 according to the area of a wall, etc., desired to be formed.
In the case of constructing a dual-layered structure, the frame panel 100 used for a structure serving as an interlayer flat slab preferably has a thickness larger by 1.5 to 2 times that of the frame panel 100 used for forming the outer and inner walls.
In addition, in the case of a building having an arch type structure such as a blind in terms of consideration of an aesthetical appearance in front of the building such as a door or a window, the arch type structure can also be formed by using the frame panel 100 as shown in FIG. 5 according to the present invention.
After the framework of the building is constructed by using the frame panel 100, a finishing material such as mortar is sprayed (jetted) to finish the exterior of the frame panel 100, without casting concrete or without using a stiffener, and thereafter, tiles or stones are attached to the interior of the building to complete the construction work.
In this case, the finishing material such as mortar is, preferably, sprayed such that the bent portions 121 of the metal wire 120 exposed from the expanded synthetic resin 100 of the frame panel 100 cannot be exposed from the finishing material such that the metal wire mesh 130 are completely buried.
Thus, compared with the conventional art in which the materials such as reinforced concrete, etc., are used to form a structure, the assembly unit 100 for buildings according to the present invention is superior in that the assembly unit is quite light, the materials can be easily carried, and the construction duration can be shortened considerably by omitting the sequential processes of making a concrete form, casting concrete, and curing the concreted surface.
In addition, because the weight of the frame panel 100 is light, the stability of a worker can be secured, and because the frame panel 100 is simply combined through welding, the surrounding environment of the construction site will not be degraded due to casting of concrete and curing of concrete surfaces.
Further, when the frame panel 100 filled with the expanded synthetic resin 110 is applied to a building, good soundproofing can be obtained without installing additional soundproofing.
It should be understood that the embodiment of the present invention as described may be modified in many ways. Such modifications are not to be regarded as departure from the spirit and scope of the invention, and all such modifications, as would be obvious to one skilled in the art, are intended to be included within the scope of the following claims.

Claims

1.-9. (canceled)

10. An assembly unit for buildings, comprising:

one or more expanded synthetic resin blocks disposed side by side, each of which having a top surface, a bottom surface, a first side surface, a second side surface, a front surface, and a rear surface, wherein two neighboring expanded synthetic resin blocks contact with each other on the side surfaces;

one or more metal wires embedded in each of the one or more expanded synthetic resin blocks generally in a first direction from the front surface to the rear surface, and fluctuating in a zigzag manner in a second direction perpendicular to the first direction, wherein each of one or more metal wires comprises a plurality of bent portions exposed from the front and rear surfaces of the expanded synthetic resin blocks;

one or more metal wire meshes, each of which being provided over one of the front and rear surfaces of the expanded synthetic resin blocks, wherein the one or more metal wire meshes is fixedly combined with the plurality of bent portions of the one or more metal wires;

one or more first coating layers provided on one of the front and rear surfaces of the expanded synthetic resin blocks, each of which embedding some of the plurality of bent portions of the one or more metal wires;

one or more second coating layers provided on the one or more first coating layers; and

one or more third coating layers provided on the one or more second coating layers.

11. The assembly unit of claim 10, wherein the first coating layer comprises 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, 6˜13 wt % of SiO₂, 0.1˜0.8 wt % of Al₂O₃, 0.01˜0.08 wt % of Fe₂O₃, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K₂O, 0.005˜0.05 wt % of TiO₂, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO₃.

12. The assembly unit of claim 10, wherein the second coating layer comprises 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, 10˜20 wt % of SiO₂, 0.3˜0.9 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K₂O, 0.005˜0.06 wt % of TiO₂, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na₂O, 0.001˜0.007 wt % of ZrO₂, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO₃.

13. The assembly unit of claim 10, wherein the third coating layer comprises 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, 17˜25 wt % of SiO₂, 0.2˜0.15 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K₂O, 0.01˜0.07 wt % of TiO₂, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO₃.

14. The assembly unit of claim 10, wherein the expanded synthetic resin block comprises one selected from the group consisting of flame-resistant expandable polystyrene (ESP), self-extinguishable expandable polystyrene and expandable polypropylene (EPP).

15. The assembly unit of claim 14, wherein the flame-resistant expandable polystyrene comprises 5˜10 wt % of isopentane as a foaming agent and 10˜15 wt % of magnesium hydroxide (Mg(OH)₂) as a flame retardant to 75˜85 wt % of polystyrene.

16. The assembly unit of claim 14, wherein the self-extinguishable expandable polystyrene is obtained by adding 6˜15 wt % of isopentane as a foaming agent and 4˜5 wt % of carbon dioxide (CO₂) to 80˜90 wt % of polystyrene.

17. The assembly unit of claim 14, wherein the expandable polypropylene is obtained by adding 8˜12 wt % of isopentane as a foaming agent to 88˜92 wt % of polypropylene having a melting point (Tm) of 162.65° C. and density of 0.90 g/cm³.

18. The assembly unit of claim 10, wherein the one or more metal wires are embedded side by side in the expanded synthetic resin block.

19. The assembly unit of claim 10, wherein the metal wire mesh is combined with the bent portions of the metal wires through welding.

20. The assembly unit of claim 10, wherein the one or more expanded synthetic resin blocks embedding with the metal wires are disposed between the one or more metal wire meshes.

21. The assembly unit of claim 10, wherein the metal wire and the metal wire mesh comprise soft steel containing carbon of 0.12˜0.25% in iron.

22. The assembly unit of claim 10, wherein the expanded synthetic resin block has an arch shape such that an assembled expanded synthetic resin blocks for a curved object.

23. The assembly unit of claim 10, wherein the one or more metal wire meshes are connected into a cylindrical shape, wherein the first, second, third coating layers are cylindrical in shapes.

24. A method for fabricating an assembly unit for buildings, the method comprising:

forming a plurality of bent portions by bending a metal wire in a zigzag manner;

fixing the bent metal wire within a mold for shaping an expanded synthetic resin block;

injecting a synthetic resin and a foaming agent into the mold such that a certain length of the bent portions of the metal wire extrudes from front and rear surfaces of the expanded synthetic resin block to mold the expanded synthetic resin block;

positioning two metal wire mesh on both front and rear surfaces of the expanded synthetic resin block; and

welding the bent portions of the metal wire and the metal wire meshes to fix the metal wire mesh on the front and rear surfaces of the expanded synthetic resin block.

25. The method of claim 24, further comprising:

forming a first coating layer on both the front and rear surfaces or one of the front and rear surfaces of the expanded synthetic resin block and on the surface of the metal wire mesh;

curing the first coating layer;

forming a second coating layer on the first coating layer;

curing the second coating layer;

forming a third coating layer on the second coating layer; and

curing the third coating layer.

26. The method of claim 24, wherein the first coating layer comprises 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, 6˜13 wt % of SiO₂, 0.1˜0.8 wt % of Al₂O₂, 0.01˜0.08 wt % of Fe₂O₃, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K₂O, 0.005˜0.05 wt % of TiO₂, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO₃.

27. The method of claim 24, wherein the second coating layer comprises 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, 10˜20 wt % of SiO₂, 0.3˜0.9 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K₂O, 0.005˜0.06 wt % of TiO₂, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na₂O, 0.001˜0.007 wt % of ZrO₂, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO₃to, on the first coating;

28. The method of claim 24, wherein the third coating layer comprises 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, 17˜25 wt % of SiO₂, 0.2˜0.15 wt % of Al₂O₃, 0.01˜0.1 wt % of Fe₂O₃, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K₂O, 0.01˜0.07 wt % of TiO₂, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na₂O, 0.001˜0.008 wt % of ZrO₂, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO₃.