WO2007093834A1

WO2007093834A1 - Construction method of reinforced three-dimensional construction element and the construction element product

Info

Publication number: WO2007093834A1
Application number: PCT/GR2007/000008
Authority: WO
Inventors: Panagiotis Anagnostopoulos; Aimilia Anagnostopoulou
Original assignee: Panagiotis Anagnostopoulos; Aimilia Anagnostopoulou
Priority date: 2006-02-15
Filing date: 2007-02-14
Publication date: 2007-08-23
Also published as: GR1005402B

Abstract

Method of construction of a reinforced three dimensional construction element (1) comprising of two parallel metallic panels (2) that encircle the insulating material (3), where the wires of the panels are being produced by rotating a continuous wire (5, 6) and a construction element product (1) from two or more parallel metallic panels (2) which come from a continuous wire wrapped around an insulating material (3), connected with transverse connectors (9).

Description

CONSTRUCTION METHOD OF REINFORCED THREE-DIMENSIONAL CONSTRUCTION ELEMENT AND THE CONSTRUCTION ELEMENT PRODUCT

Our invention refers to a method of construction of a reinforced three-dimensional construction element (1) from two or more metal panels (2) parallel to and fixed with each other that encapsulate the insulating material (3).

The method and products details, according to the present invention, will be made clear from the following description and the attached drawings, where:

Drawing 1 represents a three-dimensional reinforced element (1) that will be produced by our method.

Drawing 2 represents a three-dimensional reinforced element in which the panel is comprised of two cages that are made of continuous wire.

Drawing 3 represents a three-dimensional reinforced element (8) in which the panel is comprised of wires (17, 18) shaped as a meander.

Drawing 4 represents a three-dimensional reinforced element (8) in which the panel is produced by the proper rotation of a continuous wire (5, 6).

Drawing 5 and Drawing 6 represent applications of the product for the construction of walls and molding methods. ^■

Drawing 7 represents in an ideal manner the configuration of connecting two neighboring three-dimensional reinforced construction elements according to the present invention.

Drawing 8 represents a flat panel (25) and a cage with parallel panels (26) which is created by bending and folding this panel (25) in a U shape.

This construction material has existed in the market for many years.

In this material the intersecting vertical and horizontal wires that make up the panels can be up to 4 mm in diameter and are welded together by fusion welding.

Also the connections between the two parallel panels which encircle the insulating material are made from wires that pass vertically towards the insulating material penetrating its surface and are welded at their ends with one fusion weld at each panel.

In this method, instead of fusion welding the panels are fastened by the use of metal connectors.

The panels are created by fastening the wires (7) at their intersections.

Also, the two parallel panels that encircle the insulating material are bind together with transverse metal connectors (9) where their one end is fastened to the wires of the one panel and the other end to the wires of the other panel (Drawing 1).

The transverse binding can accommodate for two functions, since it fastens the end of the connector at the intersection (10) of each wires sides where we have three wires fastened with one of them on the same intersection. By this way, the creation of panels is accomplished and at the same time the two panels are connected (Drawings 5 and 6).

In-between the two panels insulating material (3) is usually placed in such a manner that the transverse connectors that penetrate it, hold it in that position. The connectors can penetrate the insulating material in a slightly angled and alternating manner, so as the material to stay in the middle between the panels (Drawings 5 and 6).

In the current method for the construction of the two panels at one squared meter for each side 16 + 16 wires are approximately needed or 64 for both sides that results into 64 x 2 = 128 wire ends.

In our method we can and choose not to have any ends. This is succeeded due to the fact that the wires of the panels are produced by the rotation of one continuous wire (5, 6).

The wire is wrapped around a mould that has got the shape of the insulation, which on its turn is inserted within the mould. The wrapping is spirally made until the entire height of the mould and insulation is covered. We have chosen the distance in between the coils (Drawings 2 and 4). Afterwards another spiral winding of the mould is made at a 90° from the previous one.

So, by using these two cages the horizontal and vertical sides on both faces of the construction element (1) are created by a single continuous wire (Drawings 2 and 4).

Afterwards the penetration of the insulating material is made by the use of connectors (9) that are preferably made of metal and with the appropriate mechanism are fastened on the wires of both of the panel's (10) sides (Drawings 5 and 6).

Then the mould is pulled out resulting in the final construction element.

The recesses of the vertical and horizontal blades of the mould have such a shape so as to bend the rotating wire and create the four recesses of the continuously produced orthogonal parallelogram on the one wrapping position. Afterwards the three other recesses follow at a 90° angle from the first one.

The panel can also be created with the use of continuous wire by the following method.

With the appropriate mechanism the shape of a meander (17) is produced with the use of single continuous wire where the parallel sides have the required length of the panel sides and the meanders other parallel sides have the wanted length of the distance that we want them to have in between (Dr 3).

If two such shapes are placed one on top of the other at a 90° angle, then we get the desired horizontal and vertical wires of a panel that is under construction and its ends are connected to the wires next to them.

By the same way the other side of the parallel panel is created. After the encirclement of the insulating material and the transversal penetration and fastening (15) by the use of connectors (14), the desired constructive element is created (Drawing 8).

An alternative solution for the creation of the panel would be the following: A panel of double the size (25) is created that in sequence is bent and folded at a U shape (26). Hence, the double panel as well as the space to slide in the insulating material is created.

By bending the initial shape to the correct dimensions we can create a complete cage with the two big and small sides.

In our method we can use wire that has a diameter much larger than the 4 mm used by others.

Of course, the binding method can, also, be applied with the assembly of the panels by the analogous number of wires cut to the correct dimensions.

In this case, likewise the two previous, the binding of the intersections can be used at will either at the two intersecting wires or in conjunction with the transversal wire for a triple connection.

Until now, in order to construct a wall, the produced constructive elements are placed side by side along their length. There they are connected together by covering their connecting line with an extra piece. This occurs at the inner and outer sides of the wall.

In our spiral method and the one using the meander, the connection of each side of the construction element with its next one, is easily achieved because on their ends the wires have been bent for 90° + 90° = 180° (24) hence" offering an easy attachment with the respective wires of the next construction element (Drawing 7).

Another serious innovation that stems by the use of metallic transversal connectors as binders is that the wall being constructed by these elements can be plastered very easily. This is achieved in the following way:

The binding offers much greater toughness than fusion welding.

Hence on the spots where the sections are fastened by the use of transverse connectors, hooks can be added where the inner surface of a flat mould is attached. This occurs on both sides of the construction element. The construction element is encircled within two moulds. Afterwards, the space in between is being filled with plaster or cement (13) that, once dry, creates a smooth flat wall.

Once dry, the two opposite moulds are detached from the construction and the hooks remain encapsulated within the cement (13).

By the use of this method repetitive and time consuming application of plaster or cement layers is avoided as well as spillage of the material on the floor.

ADVANTAGES OF OUR METHOD AGAINST OTHER METHODS

First advantage

The main disadvantage of the other constructive elements is that the wires are being welded together at each intersection by fusion welding. This type of welding removes material from the wire melts it and makes it thinner. At each one square meter on both sides of the panels there are in total approximately 450 welds that comprise points of material weakening.

The only reason welds are used is to hold the wires in place until the cement is poured. Afterwards, the welds are useless and operate only on the spots where the wire has weakened.

The most important part of our innovation is that this method does not damage at any point the wires and holds them perfectly until the cement (13) is poured as well as being compliant with all countries' construction laws.

Second advantage

The existing machinery requires an installed power supply of approximately 600 KW for the production of the panels and for the transverse connections between them.

By our method the required power does not exceed 20 KW. This gives the ability to transport the machinery to the construction site. The transportation in distant locations of the construction elements is costly due to the fact that even though they have big volume their weight is low. Hence transportation energy wastes are minimal.

Third advantage

The new product can be produced in big wire diameters that reach up to 12 mm. The largest wire diameter chosen by other methods is up to 4 mm.

This way, the static force of the construction material allows more floors and roofs with larger cross sectional areas to be built.

Fourth advantage

The dimensions of the construction panels' squares can vary accordingly. Today, everybody produces the old construction elements using a standard square of 6,3 mm x 6,3 mm due to the fact that their construction method does not allow for a change in dimensions. Hence, civil engineers have to adapt to the panel capabilities and not to the requirements of their own calculations.

Fifth advantage

In many of the existing construction elements the wire is placed on top of the insulation, while regulations state for the wire to have around it approximately 1 ,5 cm of empty space so as to be sufficiently covered by the filling material. Our construction element can be produced in order for the insulation material to be held in the required distance from the panel wires. This is achieved by inclined and alternating transverse connectors of the wires that connect the two panels.

Sixth advantage

An important innovation that is being introduced through our new method is the almost automatic plastering of the wall. Until now plastering or cementing the wall has been done by shooting the mixture on it, in repetitive stages, allowing enough time to dry. With the new method our innovation allows for the construction element to be fitted with moulds (12) on its left and right. These moulds are held in place not by outer mountings but by the panels of the construction element. Due to the powerful connection of the two panels with transverse binding, we can firmly locate the hooks on the connection points. The hooks hold the flat moulds and resist the powerful stresses exerted outwards by the plastering material (13) (Drawing 5).

Thus, instead of shooting material with cement injection machinery or throwing it manually, the material is poured from the top so as after the mould is removed, the element has ready and smooth surfaces with automatic plastering. It relieves from labor work and the known mess with the dirty construction site floors. Finally, it reduces drastically the cost of construction and the time of completion.

Seventh advantage

Another important innovation of this method is that the construction elements can be produced according to the civil engineer's desired width, instead of the existing 125 cm width that the panels are being produced until now.

Hence, wider construction elements can be produced and the numerous attachments of the old narrow elements can be avoided at every 125 cm.

With the existing methods it is hard to double the width of the construction elements due to the fact that double the electrical power installed will be needed. Instead of 600 KWA it would require 1200 KWA almost doubling the price of the building blocks.

Eighth advantage

The new method of production ensures another important advantage.

Until now, the old construction elements were placed side by side and the joining line was covered with additional panels 3 m high and 30 cm wide on both sides.

The new construction element that we produce can be attached to the one next to it by the hooks that have been created on the sides at the joining spots. Thus, both a perfect join and speed of construction is achieved. The wires of the panel either created by the method of spiral or the meander method, have their ends bent at 90° + 90° = 180°. This accommodates easy joining with the respective wires of the following construction element. Ninth advantage

By the old construction elements the wires on the spots where thousands of welds occur, loose their galvanized cover and through the passage of time become vulnerable to corrosion when covered with materials that contain asbestos. In our method, due to clip binding, the galvanized surface remains intact eliminating the disadvantage of corrosion.

Tenth advantage

Another very important advantage of the NEW PANEL is its low production cost. The factors that lower its cost are two:

The first factor is that the speed of production of the new complex triples. This is achieved by the wider span of the machine. From 1 ,25 m it now goes up to 3 m, therefore the production almost triples. Second factor is that there is no longer need for the complex and expensive electrical machinery that produces fusion welding.

The binding mechanisms of the connecting wires require minimum consumption of energy. Also, the panel's creation using folding requires smaller number of mechanisms. So, the cost of manufacture for the new complex decreases significantly.

Eleventh advantage

With our method due to the construction of panels from continuous wire, we eliminate the projection of the transverse connecting wires that exist in the other methods and that protrude out of the old constructive elements. According to regulation, from these ends the minimum allowable width of plastering or cementing is measured, where in areas close to the sea it has the greatest width value.

Twelfth advantage

The requirements for wire spinning wheels are minimized allowing the minimization of space required to construct the elements. Thirteenth advantage

The new method used for the transverse connection of the two panels, which does not require fusion welding, allows for the use of stainless steel that does not corrode. Until now, they could not be used due to the fact that it is very hard to fuse weld stainless steel. Thus, in areas with strict regulations or countries with high humidity levels, the old panel has a disadvantage. The wires that penetrate the insulation are exposed and prone to corrosion.

Fourteenth advantage

The new method of production allows the production of the construction element with wires of greater cross section. So, the NEW PANEL can be used with construction beams of greater diameter and in other building works as a reinforced wall.

The following advantages also exist in construction elements of other methods, but in our method these are maximized.

- It is used for concrete and other elements in buildings of up to 3 floors, roofs, and ladders.

- Construction time of buildings shortens up to 40%.

- Our method incorporates the thermal insulation material, thus exceeding over 20-30% the traditional methods of thermal insulation.

- It has a high level of sound insulation. - It has high earthquake resistance.

- The channels for hydraulics, electrics can be easily placed without having to damage the walls afterwards.

- It is light and easy to install due to the fact that it has a height of 3 m and width of 1 ,25 m. Even a worker can transport it and place it. - It has high capabilities for aesthetically appealing constructions.

- Windows and doors can be easily installed when the block is cut to size for them to be fitted in.

Claims

1. Construction method of three dimensional reinforced construction element (1) comprising of two parallel and connected to each other metal panels (2) that encapsulate the insulating material (3) that is characterized of: the horizontal and vertical wires (4) of the parallel panels (2), which are constructed from the straight sides of an orthogonal parallelogram of a spirally shaped continuous wire (5) that its parallel sides are created at the desired distance between them, where a second spiral (6) of the same kind is created around the first at an angle of 90° creating every desired panel density of the cage also allowing the two spirals to be created by winding around the insulating material (3) at horizontal and vertical directions and a chosen wire distance from the insulating material where the intersections of the vertical with the horizontal wires are fastened by the use of a metal wire (7) or connectors of any cross-section and material by the use of an appropriate mechanism creating simultaneously each panel sides of the construction element where in order to create the three- dimensional construction element (8) the parallel sides of the panels are connected by the use of more metal connectors (9) of desired length in accordance with the distance between the two panels and these connectors go through transversally the in between insulating material (3) where each end of the connectors using a special mechanism that attaches one by one wraps around the wires of the two parallel panels preferably the connectors that wind around the intersections (10) of the panel wires of each side where a simultaneous binding of the three cross hatching wires occurs creating powerful connections so as to place the hooks (11) that are mounted on the one side of flat moulds (12) appropriate for the subsequent cementing (13) of the construction element to be connected to each other by being placed at a selected parallel position of a chosen distance where the connection is done again by an analogous length and number of connectors (14) using an appropriate mechanism where its one end (15) is fastened by rotation on the wires of the inner panels side of the one construction element so its other end to be fastened on the wires of the inner of the other panel of the second construction element creating a desired number of multiple construction elements.

2. Method as of Claim 1 is characterized as: the continuous wire (5) wraps around the insulating material (3) creating a cage that each coil has a spacing to its next one so as to create the distance between the horizontal wires of the two panels and with the same method to create the vertical wires where the second cage (6) is created by encircling the previous one at an angle of 90° where in succession using transverse connectors favorably made of metal that its ends are wrapped around the wire or the intersections of each panels side connecting rigidly the two panels together and creating simultaneously two connected panels by the use of continuous wire.

3. Method as of Claim 1 is characterized as: the vertical wires of the metal panels of construction elements each sides are produced at a meander shape (17) using an appropriate mechanism (17) using continuous wire that unrolls from a spinning wheel that the small side (18) of the shape defines the distances between the vertical sides, and in sequence using the same method the horizontal wires are created which cover at a 90° angle the vertical ones producing each side of the panel.

4. Method as of in Claim 1 is characterized as in most spots of each panels side an analogous number of hooks (11) is being placed of appropriate material and of the desired length that are fixed on the one side of the flat surface of the mould (12a) which is placed at a parallel position across the whole surface of the construction element where a second surface (12b) is placed on the other side encircling the construction element constructing a space where the plastering or cementing material (20) will be poured while the flat surface-mould using the placed hooks (21) resists the stresses exerted from the inner to the outer side, across the whole surface of the construction element, due to the internal powerful connection of the two panels where the same effect occurs on the other side avoiding the need to use external support for the moulds, enabling the mould-surface after the construction element has dried out to be released from the hooks that remain enclosed within the solidified coating material.

5. Method as of Claim 1 that is characterized as the ends (22) of the horizontal wires at the sides of the construction elements which are shaped by an appropriate mechanism at the desired shape (Drawing 7) so as when the construction elements are placed side by side to create the width of the analogous wall the shaped wire ends of one construction element to hook (24) with the respective ends of the next construction element in order to create a continuous construction element.

6. Method as of Claim 1 that is characterized as the metallic panels (2) parallel to each other that construct the construction element are able to be produced simultaneously at the point of production of the three-dimensional construction element being made from a single continuous wire and from more metal clips that their one end is fastened favorably on the intersection of the horizontal or vertical wires of the first panel that has been created while at their other end they are fastened at a respective point of the second panel that has been created in order by completing the connection the creation of the two panels along with the three-dimensional construction element (8) is completed.

7. Method as of Claim 1 that is characterized by the fact that a panel (25) with an appropriate mechanism is bent and folded in a U shape (26) in order to create the two parallel panels (2) at a desired distance between them.

8. A construction element (1) product of two or more metal panels that are in a parallel position to each other and encircle the insulating material (3) that is being penetrated by transverse connectors (9) which hold the panels together is characterized by the fact that the panels (2) are created by the horizontal and vertical wires (4) which at the intersections are fastened with metal connectors where the connection between the parallel panels is being done with metallic connectors of analogous length (9) which ends are fastened one by one (10) rotating around the respective wires of each side creating the construction element.

9. A construction element product, as described in Claim 8 that is characterized as the horizontal and vertical wires of the two panels are being made from continuous wire which is wrapped around the insulating material (3) spirally (5) by an appropriate mechanism at an adjustable distance from the insulation, in this way the horizontal wires of both sides are created (5) and with a second rotation of 90 degrees, the vertical wires of both sides are created and in sequence the metal connectors are wrapped around the intersections (10) of the horizontal and vertical wires of each side by this way creating the two parallel panels and the three dimensional construction element.

10. A product as referred in Claim 7 that is characterized as: the metal connectors (9) whose ends are fastened by fastening around them in a rotational way the wires of the two panels (10) that are made of stainless steel wire.