WO2016083292A1

WO2016083292A1 - Method for producing panels for building prefabricated houses and panels obtained by said method

Info

Publication number: WO2016083292A1
Application number: PCT/EP2015/077339
Authority: WO
Inventors: Angelo Candiracci
Original assignee: Angelo Candiracci
Priority date: 2014-11-28
Filing date: 2015-11-23
Publication date: 2016-06-02

Abstract

Panel and method for producing panels, the method comprising: forming products made of sintered expanded polystyrene (EPS) with a density between 30 and 60 kg/m3 in a mould by vapour sintering EPS beads, thus obtaining a monolithic mass, wherein at least one reinforcement element constituted by a steel grid is embedded in the mould before the moulding of the sintered EPS for attaining composite products comprising said steel grid (7), wherein - the mould is shaped with recesses and projections for obtaining panels (3, 4, 5, 6) with shaped basreliefs with seats and reliefs (8, 9, 12, 13, 14, 15, 16) for applying metalware and accessories; - in the mould there are positioned plates, strips, sections and means for supporting the steel grid (7); - the steel grid (7) and the means for supporting the metalware are arranged mutually welded and joined in the mould; wherein said method is suitable for obtaining composite panels with reinforcement steel grid (7) with connections for metalware and accessories incorporated initially so that they remain embedded mutually bound and constrained in the polymeric mass of the sintered EPS constituting the finished product.

Description

METHOD FOR PRODUCING PANELS FOR BUILDING PREFABRICATED

HOUSES AND PANELS OBTAINED BY SAID METHOD

DETAILED DESCRIPTION

State of the art

A wide variety of insulated prefabricated products aimed at meeting shelter needs in makeshift and residential positions of temporary and/or emergency type are known.

Most known solutions reveal advantages and disadvantages; however all solutions tend to combine robustness, lightness, stability, ease of transportation, insulation, salubrious, re-utilisation and cost effectiveness characteristics; however, all these solutions according to the prior art do not entirely satisfactorily meet the needs of the industry.

Objects of the invention

The main object of the present invention is to provide a method for manufacturing products and in particular panels suitable to obtain structure elements for building prefabricated residential units with the aim of meeting temporary housing needs, in particular for people forced to leave their usual homes due to natural or war calamities; as well as design products thus made.

Another object of the present invention is to attain the previous object through a method for producing products and in particular panels suitable to bear stresses deriving from their applications or suitable to be appropriately reinforced to bear said stresses without jeopardising the attainment of the other objects; in addition, it should be suitable, as much as possible, to attain and provide robustness, lightness, stability, ease of transportation, insulation, salubrious, re-utilisation and cost effectiveness characteristics; as well as designing products thus made.

Still, another object of the present invention is to attain the any one of the preceding objects through a method for producing products and in particular panels suitable to substantially incorporate any kind of accessories or coupling for accessories that may be required or useful or commonly required in the finished prefabricated product therein; as well as designing products thus made.

A further object of the present invention is to attain any one of the preceding objects through a method for producing products and in particular panels suitable to obtain prefabricated building products with lightness parameters substantially superior than any other obtained according to the prior art and simultaneously having robustness, waterproof, resistance to humidity and fireproof characteristics; as well designing products thus made.

A further object of the present invention is to attain any one of the preceding objects through a method for producing products and in particular panels suitable to obtain prefabricated building products that can be concretely applied to luxurious and prestigious constructions; as well designing products thus made.

Still a further object of the present invention is to attain any one of the aforementioned objects and products, in particular panels, made in a simple and functional manner, safe in use and relatively inexpensive considering the actual results attained therewith.

Summary of the solution concept

These and other objects are attained through the method for producing panels for building prefabricated houses, particularly for emergency humanitarian residential purposes, according to the present invention, comprising: moulding shaped panels made of high density [30 (thirty) to 60 (sixty) kg/m3] sintered expanded polystyrene (EPS); embedding at least one reinforcement element, preferably wire mesh and preferably made of steel in the mould, before moulding the sintered expanded polystyrene, to obtain composite products with reinforced armour; shaping the moulds for modelling, as much as possible, the limited diversification of the modular panels constituting the prefabricated element, differentiated according to the intended positioning as regards the base, outer walls, inner walls and roofs; for assembly parameters as regards mutual coupling complementary shapes; for functions as regards access openings and windows; providing - in the mould - accessories, tanks and ballast compartments; positioning pipings, channels, plates, strips and support means before moulding the sintered expanded polystyrene to obtain panels especially wall panels by providing spaces for installations and connections for complementary elements and accessories incorporated originally; localised co-injection of polystyrene with differentiated volume mass parameters in the mould to attain panels made of sintered expanded polystyrene with locally differentiated density for reinforcing the portions most exposed to stresses. These and other objects are also attained through panels and structures for prefabricated constructions, particularly for humanitarian emergency residential purposes, obtained through this method, comprising elements made of sintered expanded polystyrene with a density preferably comprised between 30 (thirty) to 60 (sixty) kg/m3 incorporating metal reinforcement, preferably made of electrowelded wire meshes or cages, with shapes differentiated according to intended positioning as regards the bases, outer walls, inner walls and roofs; for assembly parameters as regards mutual coupling shapes; to serve as access and window openings, supplementary partitions, tanks and ballast compartments; providing for accessories for pipings, channels, hardware and supports required for providing equipment, associated to the polymeric mass for moulding; for selectively positioning the accessory in the mould before moulding the panel, so that it projects incorporating the accessory from the origin in any position contingently designed, both on the relative surface embedded therein fully or partly; with density and sintering of the polystyrene mass possibly diversified attaining greater density and thus resistance in the positions where they are subject to most intense wear in the finished product.

Description of the attached drawings

Further characteristics and advantages of the method for producing panels for building prefabricated houses and prefabricated constructions panels and structures, particularly for emergency humanitarian residential purposes, obtained through such method, according to the present invention, shall be more apparent from the following detailed description of a preferred but non-exclusive embodiment thereof, represented solely by way of non-limiting example with reference to the attached drawings, wherein:

Figure 1 illustrates an exploded perspective view of an embodiment of a prefabricated house with the panels obtained by implementing the method according to the present invention, illustrated in a partly sectional view;

Figure 2 illustrates an exploded perspective view of an embodiment of a prefabricated house with the panels obtained by implementing the method according to the present invention;

Figure 3 illustrates a detail of figure 1;

Figure 4 illustrates a top perspective view of an embodiment of a prefabricated house with the panels obtained by implementing the method according to the present invention;

Figure 5 illustrates a front perspective view of an embodiment of a prefabricated house with the panels obtained by implementing the method according to the present invention;

Static description of preferred embodiments

Sintered expanded polystyrene, also commonly referred to as expanded polystyrene, is a thermoplastic resin derived from benzene, with lightness, isothermia, waterproof, dimensional stability, rigidity and resistance to knocks, self-extinguishing and non-toxic characteristics.

As regards lightness, EPS has low volume mass or density [from 10 (ten) to 60 (sixty) kg/m³].

As regards isothermia, it is one of the main characteristics of EPS and it is facilitated by the fact that it is 90% formed by air. This air is enclosed in cells so small to prevent the convective motions. Thus, heat transmission may occur solely by conduction, very low in the air, and by radiation, which rapidly reduces upon the multiplication of the screens made up by the walls of the cells. Remaining balanced with respect to the external air, the internal air stabilises heat conductivity over time.

As regards waterproof features and, on the contrary, permeability to water vapour, EPS is not a hygroscopic material, thus products made of EPS do not reveal inhibition phenomena by capillarity. Thus, EPS' right value of permeability to vapour allows the transpiration of the products obtained therewith, thus not vulnerable to mould and the like.

As regards dimensional stability, EPS is isotropic, given that the products obtained therewith are not subjected to tensioning, with ensuing deformation and breakage, regardless of the time of utilisation thereof; actually, there is a physical- mechanical state of balance with homogeneity of characteristics reproduced in all points of the product. Such characteristic is mainly influenced by the type of expansion the material cells have. As a matter of fact, the cell structures that expand as a whole within the space of a few millimetres of diameter are extremely regular, with almost identical micro-spheres.

As regards rigidity and reaction to mechanical stresses, the relation between stresses and deformations is linear up to 3% of deformation. Beyond this limit there is a permanent deformation of the cell structure without breakage.

As regards self-extinguishing characteristics, EPS reveals delayed flame propagation characteristics. The products tested as regards reaction to fire have resistance values solely inferior to those made of incombustible material.

As concerns non-toxicity and biological tolerance, EPS is not toxic, it is not represent a source of nutrition for any living being, micro-organisms included; EPS does not rot, it is not attacked by mould and it is completely recyclable, biologically neutral, neutral to odour and neutral to contact with skin.

As regards production technology, expanded polystyrene should be subjected to a series of transformation processes directly related to the intended use thereof before being used.

At the beginning, the material is in form of fine beads, from one to three millimetres of diameter, added with an expanding agent; the production of semi-finished products and polystyrene - expanded polystyrene - products occurs in three main stages.

Pre-expansion: the expandable polystyrene beads are pre-expanded, generally by means of vapour at a temperature exceeding 90 degrees centigrade, in the so-called pre- expander. In the pre-expansion treated with vapour, the raw material softens and the expanding agent evaporates, causing the swelling of the beads. Following the evaporation of the expanding agent, the beads amplify up to sixty times their initial volume. The duration and intensity of this first operation determine the volume mass of the finished product. A closed cell structure, fundamental for the subsequent use as heat insulator, is formed in this process in the expanded polystyrene beads. The degree of expansion, which essentially depends on the duration of heat treatment in the pre- expander, determines the apparent volume mass of the products made of expanded polystyrene and thus all their physical characteristics.

Maturation of the pre-expanded product: At this stage, the polystyrene beads are stationed for a given period of time in aerated silos. Upon cooling, the expanding material and water vapour residues condensate in the single cells. The vacuum thus formed is nullified by the air which spreads in the cells; thus, the pre-expanded polystyrene or expanded polystyrene beads reach the stability required for the subsequent steps.

Modelling the product: pre-expanded and stabilised polystyrene beads may thus be transformed into products or semi-finished products in various ways.

As regards moulding blocks and cutting polystyrene or sintered expanded polystyrene slabs; it is the most used system, the block-making device, constituted by a parallelepiped-shaped element provided with micro-holes for the inlet of vapour on all sides, is filled with polystyrene or expanded polystyrene beads and subjected to a new injection of the saturated vapour; temperatures between 110 - 120 degrees centigrade are attained at this stage; the beads swell further and join each other due to their internal pressure, i.e. they are sintered. The higher the EPS densities, the more the block is subjected to pressure such to facilitate a better sintering. After a brief cooling period, the blocks are extracted and preferably stored for a variable period of time ranging from a few days to two months, a period during which they reach the stability required for the various applications. From here, the expanded polystyrene blocks are picked up for cutting into panels, which occurs with hot wire cutting lines and other possible mechanical operations, such as shaping using numeric control pantographs or by milling.

For moulding panels or other expanded polystyrene products: The production process is the same described for the production of blocks but the EPS panels are moulded singularly in special numeric control automatic machines. This leads to the advantage of directly obtaining the desired shape, without further mechanical machining processes, sintered beads even in this case; in the EPS, good sintering, i.e. the "bonding" of the beads to each other is very important, actually it is crucial. The more the EPS has high density, the more the block is subjected to pressure such to facilitate a better sintering.

For extrusion-drawing: subsequently to polymerisation, polystyrene or expanded polystyrene is joined to the expanding agent and other possible additives in a drawing machine, which mixes the ingredients in molten state and extrudes the mixture from a die, usually in form of a flat panel, which immediately sinters and expands and stiffens in the expanded form as it cools.

According to the prior art, the sintered expanded polystyrene, also referred to as EPS or expanded polystyrene, products are mainly if not exclusively utilised for filling sealed chambers for floating, in the packaging and building industry, for obtaining heat and sound insulations as well as usually prefabricated composite products made of concrete and plaster with heat and sound insulation, fireproof and seismic resistance characteristics.

According to the present invention, the characteristics of expanded polystyrene, also referred to as EPS or expanded polystyrene, concretely apply to the building industry, but not in combination with concrete, plasters and various mortars like in the prior art but rather as independent self-bearing panels suitably reinforced, with an exposed surface, accessorised and equipped with an assembly for accessories right from the relative constitution, diversified according to intended positioning, provided in all- comprehensive packets and finally mutually assembled at the laying site, to immediately obtain the fabricated construction for immediate use.

Implementing the method according to the present invention, the obtained product is a moulded panel obtained by moulding in a special dedicated mould, as the other aforementioned sintering technologies are not suitable for the purpose. The single moulds may obviously vary in terms of numbers, grouped in the entirety of the moulding machine (preferably of the latest numeric control generation), the beads in said mould being subjected to sintering directly obtaining the desired shape and overall dimension of the product, as well as the relative density, established by the mould and the incoherent spherule supply parameters characterizing the beads, vapour injection and ensuing qualified sintering.

The method according to the present invention provides, as primary embodiment, the moulding of composite construction assembly, by aggregating an armour preferably made of steel to the sintered expanded polymeric mass, still preferably of the high density type [from 30 (thirty) to 60 (sixty) kg/m3], by embedding rod-like steel elements therein, preferably preassembled to constitute a mesh or cage of electrowelded elements, still dimensioned and shaped as a function of the shape of the product and/or assembly needs and/or assembly and joining application means; arranging such steel rod-like elements in the polystyrene expansion mould; pouring - into the mould - incoherent granules or beads obtained in the from the polymerisation of styrene, with suitable grain size and volume to attain a high density finished product [from 30 (thirty) to 60 (sixty) kg/m3]; expansion and sintering i.e. grouping incoherent polystyrene through contact with water vapour and temperature exceeding ninety degrees injected into the mould and the ensuing entrapment of the reinforcement in the monolithic mass thus attained to obtain a solid geometry, defined by the mould, of polystyrene or reinforced sintered expanded polystyrene.

Another embodiment of the method according to the present invention, simultaneously actuatable to others described hereinafter, provides for shaping the moulds with recesses and projections to obtain shaped bas-relief products, for example channels, guides, reliefs, teeth, shaped in general, for application of metalware and/or decoration during the assembly of the pieces moulded in the process aimed at attaining the finished product.

Another embodiment of the method according to the present invention, simultaneously applicable to others described above and hereinafter, provides for moulding the composite construction assembly by aggregating metalware to the sintered expanded polymeric mass, still preferably of the high density type [from 30 (thirty) to 60 (sixty) kg/m³], by positioning - in the moulds - plates, strips, sections or means for supporting further metalware intended to support the finished product; suitable positioning of the elements through retentions for maintaining the elements on site during the subsequent filling, injection and moulding steps: pouring - into the mould - granules or incoherent beads obtained from the polymerisation of styrene, with grain size and volume suitable for attaining a high density finished product [from 30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees centigrade and ensuing obtainment of a monolithic mass with solid geometry, defined by the mould, of polystyrene or sintered expanded polystyrene, incorporated - where required - in the appropriate arrangement on the surface or under the surface, metal portions or materialised portions, suitable to receive the anchoring means or the functional means to assemble and/or use the finished product.

Another embodiment of the method according to the present invention, simultaneously applicable to others described above and hereinafter, provides for moulding the composite construction assembly by aggregating sheets or panels to the sintered expanded polymeric mass, still preferably of the high density type [from 30 (thirty) to 60 (sixty) kg/m³] , by positioning - in the moulds - sheets or panels or means constituting or supporting the finished product, on whose surface they project lodged; without prejudice to the other actuation steps of the method above for the embedment of metalware.

Another embodiment of the method according to the present invention, simultaneously applicable to others described above and hereinafter, provides for the localised co -injection of polystyrene with differentiated parameters of volume mass in the same mould, pouring - in the mould - granules or incoherent beads obtained from the polymerisation of styrene, with differentiated grain size and volume mass in the various areas of the mould according to a predetermined distribution, and adjustment of the automatic pouring and injection means for attaining a localised high density finished product [from 30 (thirty) to 60 (sixty) kg/m³]; expansion and sintering namely incorporating the incoherent polystyrene through contact with water vapour injected into the mould at a temperature greater than ninety degrees centigrade and ensuing obtainment of a monolithic mass thus obtained, to attain a solid geometry, defined by the mould, of polystyrene or sintered expanded polystyrene constituting the product made of the locally differentiated density sintered expanded polystyrene, for reinforcing the portions of the finished product, that the product contingently contributes to forming, exposed to most stress in use.

Dynamic description of the preferred embodiment

Thus, having completed the static description of preferred embodiments of the method for producing panels for building prefabricated houses and panels and structures prefabricated constructions, particularly for humanitarian emergency purposes obtained with the method according to the present invention, below is the dynamic description, or the relative operation, application and use of the panels obtained with the method according to the present invention:

The panels and products obtained to implement the method, according to the present invention, have mechanical characteristics similar, where not positively increased or improved, to analogous structures made of plastic, composite and wooden material according to the prior art, for obtaining prefabricated building structures adapted to meet emergency, temporary and even permanent residential housing needs; this being due to the fact that sintered expanded polystyrene, with a density comprised between 30 (thirty) and 60 (sixty) kg/m³, is suitable to support compression stresses comparable to those of the best plastic, composite and wooden materials; while, as regards the traction such synthesis material reveals greater opposition to cracking, i.e. greater elasticity, than the best plastic, composite and wooden material, wherein suitably supported with a reinforcement, especially metal steel wires assembled in meshes or cages embedded therein.

As a matter of fact, in the panels according to the present invention thus reinforced in the core, the traction stresses are countered by the supplementary synergic supporting action of the steel grid or cage, thus obtaining products comparable, according to structural and mechanical features, to products made of the best plastic, composite and wooden materials but lighter and with considerable advantages in terms of waterproof, insulation, transpiration, organic inertia, stability, ease of transport, capacity to be reutilised and cost effectiveness characteristics; these characteristics lead to considerable advantages in terms of comfort and salubriousness of the housing structures thus obtained. These products may be obtained in any shape and dimension according to the contingent implementation and project requirements, through suitable conformation of the moulds for sintering the expanded polyethylene.

Applying one or more of the embodiments of the method, the specific implementation and design needs of any kind may also be met by suiting the product thereto.

For example, in the basic embodiment, or the one that provides for a metal reinforcement, preferably made of electrowelded wire mesh or cage, the joining between the panels/products and application of metalware, to attain the finished product, i.e. the prefabricated building product, may be attained using the usual fixing means, such as screws and the like, which penetrate into the expanded body and are constrained to the internal meshes, contingently conceived with a mesh dimensioned to suit the purpose, as well as shaped to maximise the anchoring function of the assembly means, besides reinforcement.

Alternatively and/or additionally, actuating other embodiments according to the method, the mould may be shaped with receptacles complementary to the shape of any metalware and accessory needed for assembly and use; so as to assemble the metalware to the product subsequently to forming the latter, in reception seats and recesses specifically conceived during moulding and derived from the conformation of the mould.

Still alternatively and/or additionally, implementing other embodiments according to the method, any metalware and accessory required for the assembly may be associated to the polymeric mass during moulding, selectively positioning the accessory in the mould before moulding the product, so that it rests incorporating the accessory from the origin in any position contingently to the conceived design both on the relative surface and entirely embedded therein fully or partly.

This embedding of accessories in the polymeric mass is advantageously combined with the embedding - in the mass - of reinforcement armours, by welding or however constraining the reinforcement accessories and structuring the accessories even as a function of such mutual assembly; for example a rectangular U-shaped section, with base meant to remain on the surface of the finished product to constitute a metal strip coplanar thereto, with prongs welded apically to the internal reinforcement; wherein the prods bear holes or interruptions of any kind so that the polymeric mass penetrates into the relative internal and expands therein and sinters incorporating the assembly.

Further alternatively and/or additionally, other embodiments according to the method provide for that the density and sintering of the expanded polystyrene mass may be diversified in the finished product, with the aim of attaining greater density and thus resistance in positions subject to intense wear;

In the figures reproduced in the attached drawings, examples of panel products for building prefabricated houses, particularly for emergency humanitarian residential purposes, obtained according to the production method of the invention, are represented by way of example:

In figure 1, a prefabricated construction for example a bedsitter house represented in exploded view, particularly for temporary residential purposes especially for humanitarian emergency purposes is indicated in its entirety with 1.

The prefabricated structure 1 is fully obtained by assembling panels and panel structures, as described in detail hereinafter, comprising elements made of sintered expanded polystyrene with a density preferably comprised between 30 (thirty) to 60 (sixty) kg/m³ incorporating metal reinforcement, preferably made of electrowelded wire meshes or cages, with shapes differentiated according to intended positioning as regards the bases, outer walls, inner walls and roofs; for assembly parameters as regards mutual coupling shapes; to serve as access and window openings, supplementary partitions, tanks and ballast compartments; providing for accessories for pipings, channels, hardware and supports required for providing equipment, associated to the polymeric mass for moulding; for selectively positioning the accessory in the mould before moulding the panel, so that it projects incorporating the accessory from the origin in any position contingently designed, both on the relative surface embedded therein fully or partly; with density and sintering of the polystyrene mass possibly diversified attaining greater density and thus resistance in the positions where they are subject to most intense wear in the finished product.

The prefabricated product 1 defines an internal compartment 2 by means of panel products; more precisely: base panels for support against the ground, which are ten consecutive coplanar panels in the described illustrated example , arranged in two rows, between which they are mutually constrained in pairs through supplementary couplings 8 are indicated with 3; in alternative embodiments still falling within the scope of protection of the claims outlined hereinafter, these base panels 3 may be variously dimensioned, in particular and preferably conceived with more extended dimensions, with the aim of reducing the number thereof considering the same amount of covered area, by using larger moulds; it should be observed that this applies to all categories of panel products described herein. the base panels 3, preferably made with the highest density possible to bear highest stepping wear possible (unless where the surface in question is protected with carpets, films or varnishes), have guide coupling and retention perimeter groves 9, for lateral 4, front 5 and partitioning wall panels;

the base panels 3 may also have median compartments 10 closed by concealing panel covers 11, preferably for containing sand, gravel or pebbles (materials that can be obtained at any laying site), with the aim of serving as ballast and holding the entire prefabricated product stationary, the prefabricated product also being possibly alternatively or additionally pegged;

The base panels 3, just like all lateral 4, front 5, partitioning (not shown) and roof 6 walls hereinafter, are represented partly sectioned in figure 1 to expose the core made of electro welded steel wires that form the armour 7 thereof.

The lateral wall panels 4 have - at the lower part and upper part - tapered edges 12 for insertion into the perimeter grooves 9 of the base panels 3 and in the corresponding supplementary grooves 13 of the roof panels 6; in addition, they may have male/female coupling lateral edges and window openings 14; internally, they are shaped with vertical guide coupling and retention grooves 15, for front 5 and partitioning (not shown) wall panels.

The front wall panels 5 have - positioned in perimeter fashion - tapered edges 12 for insertion into the perimeter grooves 9 of the base panels 3 in the vertical panels 15 in the lateral wall panels 4 and in corresponding supplementary grooves 13 of the roof panels 7; in addition, they have access openings 16 and window openings 14. The partitioning panels, not illustrated, are structured to be associated to the lateral wall panels and/or roof panels, so as to be able to partition or multi-partition the internal compartment 2 into several compartments of the desired dimensions.

The roof panels 6 are structured to form a double slope roof, on whose ridge there may be fixed a suitably angled plate tile.

In the alternative embodiment of the prefabricated product 1 illustrated in figure 5, the roof panels 17 are instead obtained in a flat shape, identical to the base panels 3 and like these possibly provided with compartments 10, closed with covers 11, which serve as water tanks in the roof panels 17.

During assembly, all panels may be mutually joined even by means of edge pins, made of any material suitable for the purpose, in preformed seats or to be obtained on site.

In the light of the above, both regarding the method for producing panels made of reinforced polystyrene panels and as regards their mutual assembly to form the prefabricated product, it is clear that the aforementioned can be produced quickly; packaged in packagings or kits containing all components, fixing means, work equipment, accessories; it can be quickly transported in large numbers to emergency sites due to lightness and compactness thereof; it can be quickly laid on site using ballast foundation which should definitely be available on site; it can be utilised permanently in relatively comfortable terms, under any weather conditions, at least much more comfortable than currently possible with existent structures according to the prior art, to meet the same needs; lastly, the structure may be disassembled and re-utilised or recycled in an eco-friendly manner, through simple technologies implementable in any country and place.

Alternative embodiments

It is obvious that in further alternative embodiments, still falling within the concept solution of the implementation example illustrated above and claimed below, the method for producing panels for building pre-fabricated houses and panels and structures of prefabricated constructions particularly for humanitarian emergency residential purposes obtained with such method according to the present invention, may also be implemented and obtained differently, through equivalent technical and mechanical solutions still falling within the scope of protection illustrated and claimed below;

In particular:

the product or panel may also vary in terms of dimensions and shape depending on the mould or technical and design requirements of the prefabricated product it should contribute to make;

the steel cage, or internal reinforcement, may be variously dimensioned and shaped, mutually constrained and bound in the respective composition elements;

any plurality of elements forming the internal reinforcement or associated to the internal reinforcement may be left on the surface or projecting, protruding, on the surface of the product to join to other products in the assembly.

the base panels may also be supplemented or even replaced with a concrete cast; the panels may be protected using varnish, especially polyurethane varnish, which harden the surface thereof;

though the structure is explicitly conceived for temporary residential housing purposes, the concept of structuring the panels, accessories, assembly and prefabrication according to the present invention may also easily apply to buildings intended for permanent residential housing purposes such as detached houses and flats even of the multi-storeyed type; in this extended embodiment the shapes of the panels shall definitely be larger though maintaining the modularity thereof, be of a wide variety, considering greater complexity of the final product, still maintaining the same solution concepts and advantages in terms of lightness, cost effectiveness, ease of assembly, and laying on site as well as robustness, waterproof, aseptic, resistance against humidity and fireproof characteristics.

Advantages of the invention

As evincible from the detailed description above of preferred but non-exclusive embodiments, the method for producing panels for building prefabricated houses and panels and structures for obtaining prefabricated constructions, particularly for humanitarian emergency residential housing purposes, obtained through the method according to the present invention, offer advantages corresponding to the preset and other objects: it introduces a radical innovation in the construction of prefabricated products especially for makeshift, temporary and emergency residential needs, contrary to the prior art which provides for expanded sintered polystyrene substantially only as a filler for other materials or associated thereto in various ways, thus considerably increasing the structural value and bearing capacity, reinforced - to this end - without requiring surface coating finishing operations, the latter still being applicable but tendentially surplus in the economy of the method according to the present invention and products attained therewith.

Such radical innovation is introduced simultaneously obtaining results and advantages from the modellability characteristics for moulding and sintering expanded polystyrene in terms of shaping required to assemble and associate to the assembly means both after and before moulding, attaining differentiated solidity and maximum lightness.

The method for producing panels, for building prefabricated houses and the panels and structures for prefabricated constructions particularly for humanitarian emergency residential purposes, obtained through the method according to the present invention, supplement a simple, practical, modular and polyvalent solution concept to obtain a product suitable to constitute a valid and practical alternative embodiment with respect to the elements according to the prior art, and a panel construction element for the building prefabrication industry with unparalleled characteristics of robustness combined with lightness, with immense advantages in terms production simplicity and modularity, ease of storage, transport and laying on site considering its lightness, comfort of use due to the insulation, waterproof and transpiration characteristics thereof as well as its hygienic advantages considering that it is not vulnerable to mould and parasites and its ecological tolerability due to the fact that it is relatively easy to recycle and implementable anywhere without requiring particular technologies.

The robustness, lightness, stability, easy of transport, waterproof, insulation, salubriousness, re-utilisation and cost effectiveness characteristics of the material make it particularly suitable for emergency residential housing purposes and the implementations according to the invention allow these characteristics to be concretely applied for construction materials without any additional material save reinforcing the service elements. PAGE LEFT BLANK INTENTIONALLY

KEY TO REFERENCE NUMBERS

prefabricated construction in its entirety

internal compartment of the prefabricated structure

base panels

lateral wall panels

front wall panels

pitched roof panels

electrowelded steel wire mesh reinforcements

complementary couplings of the base panels

guide, coupling and retention base panel perimeter grooves for the lateral, front and partitioning walls

median interspaces of base panels and flat roof

panel covers of the median interspaces of base panels and flat roof

tapered edges of the coupling panels in the retention grooves of the panels retention grooves of the roof panels

window openings

vertical grooves of the lateral wall panels

access openings

flat roof panels

Claims

1) Method for producing panels, prefabricated products and frames for the furnishing industry, characterised in that it comprises forming shaped products made of sintered expanded polystyrene (EPS) with high density comprised between 30 and 60 kg/m3 in an expanded mould and vapour sintering granules or incoherent beads obtained from the polymerisation of styrene and ensuing obtainment of a monolithic mass with solid geometry obtained from the mould and embedding in the mould at least one reinforcement element constituted by a steel grid before the moulding of the sintered expanded polystyrene for attaining composite products with reinforcement armour means, wherein

the mould is shaped with recesses and projections for obtaining panels (3, 4, 5, 6) with shaped basreliefs with seats and reliefs (8, 9, 12, 13, 14, 15, 16) for applying metalware and accessories for mounting and/or using the finished product;

in the mould there are positioned plates, strips, sections and means for supporting the metalware (7) before the moulding of the sintered expanded polystyrene;

in the mould the metalware (7) and the means for supporting the metalware (7) are mutually arranged welded and joined in the mould;

for obtaining composite panels (3, 4, 5, 6) with reinforcement armour means (7) with connections for metalware and accessories for mounting and/or using the finished product incorporated initially so that they remain embedded mutually bound and constrained in the polymeric mass of the sintered expanded polystyrene constituting the finished product.

2) Method according to claim 1, characterised in that it comprises the localised co- injection of polystyrene with differentiated parameters of volume mass in the same mould for obtaining panels (3, 4, 5, 6) made of sintered expanded polystyrene with locally differentiated density for reinforcement - in the finished product - of the most stressed portions during use.

3) Method according to claim 1 or 2, characterised in that it comprises forming the composite panel (3, 4, 5, 6), through the aggregation of the armour (7) made of steel to the high density sintered expanded polymeric mass, comprised between 30 and 60 kg/m³, by embedding - therein - steel rod-like metalware, preassembled to constitute a grid or cage of electrowelded elements (7), variously shaped and configured as a function of the shape of the product (3, 4, 5, 6) and/or assembly needs and/or application needs of assembly and joining means; positioning such armour (7), in the expanded mould of the polystyrene; furthermore comprising:

arrangement - in the mould - of plates, strips, sections or means for supporting the further metalware and accessory means intended to supplement the finished product;

positioning of the elements through retention for maintaining the elements in loco in the subsequent filling, injection and moulding steps;

positioning such steel rod-like elements (7), preassembled to constitute a grid or cage of electrowelded elements (7), associated to said plates, strips, sections or means for supporting the further metalware and accessory means intended to supplement the finished product, in the expanded mould of the polystyrene;

thus ensuing entrapping of the armour (7) and the support means in the monolithic mass (3, 4, 5, 6) thus obtained to attain a solid shape, obtained from the mould, made of reinforced sintered expanded polystyrene provided with metalware and/or support means for metalware and accessory means constrained to the armour (V).

4) Method according to any of the preceding claims, characterised in that it comprises localised co-injection of polystyrene with differentiated parameters of volume mass in the same mould; pouring - into the mould - the granules or incoherent beads obtained from the polymerisation of styrene, with grain size and volume mass differentiated in the various areas of the mould, according to a predetermined distribution; adjustment of the means, preferably automatic, for pouring and injection for attaining a finished product with localised high density comprised between 30 (thirty) and 60 (sixty) kg/m³; expansion and sintering, that is incorporating the incoherent polystyrene through contact with water vapour injected preferably at a temperature greater than ninety degrees centigrade; ensuing differentiated sintering in the monolithic mass as obtained, to attain a solid shape (3, 4, 5, 6), obtained from the mould, of products made of locally differentiated density sintered expanded polystyrene, for localised reinforcement of the portions subjected to more stress in the use of the finished product that the contingently moulded product shapes or contributes to shape.

5) Panel products for building prefabricated houses, particularly for humanitarian emergency housing purposes obtained through the method according to any of the preceding claims, characterised in that they comprise a structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³, incorporating a metalware armour (7), made of a steel grid or cages made of electrowelded steel networks (7).

6) Panel products for building prefabricated houses according to claim 5 obtained through the method according to any of claims 1 to 4, characterised in that said metalware armour (7) incorporated embedded in the products has size and shape such to interact with fixing means, such as screws and the like, which penetrate into the expanded body (3, 4, 5, 6) and are constrained into the internal meshes (7), contingently conceived with grid dimensioned suitably for the purpose, as well as shaped for maximising the function of anchoring as well as armouring the assembly means.

7) Panel products for building prefabricated houses according to claim 5 or 6 obtained through the method according to any of claims 1 to 4, characterised in that they comprise a structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³ shaped with metalware armour grids complementary to the shape of any metalware and accessory suitable for assembly and use, for assembling the metalware to the product (3, 4, 5, 6) subsequently to the constitution thereof, in seats and reception recesses specifically conceived during moulding and deriving from the configuration of the mould.

8) Panel products for building prefabricated houses according to any of claims 5 to 7 obtained through the method according to any of claims 1 to 4, characterised in that they comprise a structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³ incorporating any metalware and accessory suitable for the assembly and use associated to the polymeric mass in moulding constancy, for selectively arranging the accessory in the mould before moulding the product, so that the product remains incorporating - from the origin - the accessory in any position suitably designed, both on the relative surface and, fully or partly, embedded therein.

9) Panel products for building prefabricated houses according to any of claims 5 to 8 obtained through the method according to any of claims 1 to 4, characterised in that they comprise a structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³, incorporating a metalware armour (7), made of a steel grid or cages made of electrowelded steel mesh (7), to which there is constrained or welded any metalware and accessory suitable for the assembly and use associated to the polymeric mass in moulding constancy, for selectively arranging the accessory in the mould before moulding the product, so that the product remains incorporating - from the origin - the accessory in any position designed contingently, both on the relative surface and, fully or partly, embedded therein and stably constrained to armour means.

10) Panel products for building prefabricated houses according to any of claims 5 to 9 obtained through the method according to any of claims 1 to 4, characterised in that they comprise a panel structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³ with polystyrene mass density and sintering diversified so as to attain greater density and thus resistance in the arrangements subject to more intense wear in the finished product.

11) Panel products for building prefabricated houses according to any of claims 5 to 10 obtained through the method according to any of claims 1 to 4, characterised in that they comprise a panel structure (3, 4, 5, 6) made of sintered expanded polystyrene with a density comprised between 30 and 60 kg/m³ incorporating any plurality of elements constituting the internal metalware armour (7) or associated to the internal metalware armour (7) projecting in the surface or projecting on the surface of the product for the incorporated joining to other panel structures in assembly.

12) Panel products for building prefabricated houses according to any of claims 5 to 11 obtained through the method according to any of claims 1 to 4, characterised in that they comprise reinforced (7) base panel structures of base (3) for resting against the ground made using high density material for fighting greater treading wear provided with perimeter means (9) for the coupling and retention for side lateral wall panel structures (4), front lateral wall panel structures (5) and central wall panel structures.

13) Panel products for building prefabricated houses according to any of claims 5 to 12 obtained through the method according to any of claims 1 to 4, characterised in that they comprise reinforced (7) base panel structures (3) provided with recesses (10) preferably closed by occlusion panel structure covers (11) for containing sand and/or gravel and/or pebbles and/or any ballast material.

14) Panel products for building prefabricated houses according to any of claims 5 to 13 obtained through the method according to any of claims 1 to 4, characterised in that they comprise reinforced (7) side lateral wall panel structures (4) and reinforced (7) front lateral wall panel structures (5) provided with perimeter coupling and retention means (12) for fixing to said perimeter coupling and retention means (9) said base panels (3) and for fixing to corresponding perimeter coupling and retention means (13) said cover panels (6 - 17), as well internally shaped with means (15) for the vertical coupling and retention of said side lateral wall panel structures (4), said front lateral wall panel structures (5) and said central wall panel structures.

15) Panel products for building prefabricated houses according to any of claims 5 to 14 obtained through the method according to any of claims 1 to 4, characterised in that they comprise reinforced central wall panel structures having perimeter coupling and retention means for the alternative fixing to the means (15) for the vertical coupling and retention in the side lateral wall panel structures (4) and the front lateral wall panel structures (5) and in corresponding complementary means (13) for the coupling and retention of the panel covers (6 - 17) so as to divide or multi-divide the internal compartment (2) of the prefabricated construction (1) into several compartments.

16) Panel products for building prefabricated houses according to any of claims 5 to 15 obtained through the method according to any of claims 1 to 4, characterised in that said side lateral wall panel structures (4), said front lateral wall panel structures (5) and said reinforced central wall panel structures (8) have window compartments (14) and access compartments (16).

17) Panel products for building prefabricated houses according to any of claims 5 to 16 obtained through the method according to any of claims 1 to 4, characterised in that said cover panels (6) are structured to form a double slope roof.

18) Panel products for building prefabricated houses according to any of claims 5 to 17 obtained through the method according to any of claims 1 to 4, characterised in that said cover panels (17) are structures to form a flat shape.

19) Panel products for building prefabricated houses according to any of claims 5 to 18 obtained through the method according to any of claims 1 to 4, characterised in that said cover panels (17) structured to form a flat shape are provided with recesses (10) preferably closed by occlusion panel structure covers (11) for containing water and serve as tanks.