WO2017089930A1

WO2017089930A1 - Mould and production method for a pre-assembled modular wall

Info

Publication number: WO2017089930A1
Application number: PCT/IB2016/056920
Authority: WO
Inventors: Eduardo Antonio NIÑO BARBOSA
Original assignee: Niño Barbosa Eduardo Antonio
Priority date: 2015-11-27
Filing date: 2016-11-17
Publication date: 2017-06-01

Abstract

The pre-assembled modular wall for creating impermeable divisions and the method for producing the PVC wall, comprising side guides with male-female connectors and corner connectors, are intended for the construction of walls using male-female sections that can be quickly fitted together, as well as comprising corner connectors, such that a wide variety of construction shapes is possible. The panels are arranged to be filled with concrete and an internal connection is provided between panels in order to facilitate filling. The panels and the method for producing PVC panels, comprising side guides with male-female connectors and corner connectors for the construction of impermeable walls, are intended for use in technological sectors involved in lightweight construction, masonry, civil engineering and environmentally-friendly and -beneficial structures.

Description

MOLD AND MANUFACTURING PROCESS FOR MODULAR WALL

PRE-ASSEMBLED FOR WATERPROOF DIVISIONS IN PVC WITH SIDE GUIDES MALE CONNECTORS - FEMALE AND CORNER CONNECTOR OBJECT OF THE INVENTION:

The present invention relates to a Panel and its manufacturing process, whose function is the construction of walls by assembled sections with male and female shapes that fit quickly, which are also waterproof since they are made of a material of high impact resistance and to wear as well as being waterproof, as is rigid PVC. It also has corner connectors that allow a variety of construction forms; These panels are arranged to be filled with concrete and have internal communication between panels to facilitate filling. TECHNOLOGICAL SECTOR:

The Panels and the manufacturing process of PVC panels with male-female connecting side guides and corner connector for the construction of waterproof walls, is within the technological sectors related to light construction, masonry, civil construction and constructions They help and comply with the care of the environment.

STATE OF THE TECHNIQUE:

Since ancient times the efforts that man has made to develop a place to protect and house his most valuable possessions and his family, also the use of areas dedicated to rest and privacy to achieve their well-being, in addition to obtaining their achievements are recognized in a space that is more economical and does not bring a great impact on the environment; This results in a group of very similarly shaped elements, but in turn with a very different essence and set of characteristics, according to the needs of the end user and their environment, is the case of the following above mentioned then: Patent W09324714 dealing with a structural thermoplastic system, structural components therefor, and method of production thereof in which the structural components are extruded from a thermoplastic material that contains a flowable reinforcing component through a nozzle of extrusion and structural components that are configured for interlocking interlocking.

Patent W09428262 refers to an elongated thermoplastic extruded construction component for use in the construction of a thermoplastic building structure, said component of the presentation of spaced interlocking means extending the length thereof for sliding interlocking coupling with the thermoplastic member coupling, and at least one longitudinally extending web that supports said spacing interconnection means spaced in relation to said band having a plurality of cutting openings therethrough into said interconnecting means spaced apart along its length.

In its most common form the component is extruded with a core of reinforced thermoplastic material that has a soft coextruded skin that covers the exposed surfaces thereof and is rectilinear that has spaced flat walls connected in spaced relationship by spaced flat bands that extend the length thereof, the walls spaced holes being provided within at least adjacent to a longitudinal edge spaced inwardly projecting with interconnecting means extending longitudinally thereof for mutual engagement with a coupling component, at least one of said Bands that have a series of circular holes cut from it along its length with the perimeters of said space between said interlocking means protruding inwards.

WO9533106 refers to elongated structural hollow extruded thermoplastic components of rectilinear cross-section formed for the interlocking assembly for use in construction of a modular building on a support base, characterized in that each of said components is a coextrusion of a substrate that includes reprocessed plastic material and a thin smooth thermoplastic skin protection that covers surfaces of the wall of said component that are exposed when interlocking mounted with coupling components , each of said component that is with core to provide a predetermined pattern of holes spaced along the length of the walls thereof that become internal walls when interlocking itself mounted with coupling components and the holes of Coupling components be on record to provide internal flow passages between them with the "corings" providing a power supply of reprocessed plastic stock substrate.

Considering the above, as the closest art states to the invention, it can be clearly seen how they present physical and structural characteristics, design features, in addition to a series of additional molds and processes that do not solve the technical problem of having a Pre-assembled modular wall for divisions that are also waterproof for the different cases in which they can be used. Among the differences it is seen that in the previous ones a series of panels and connectors are used for a simple composition of a wall, it is observed that additional hardware and rods must be used to tie the walls, it is observed that a a greater number of molds that imply higher costs and higher maintenance costs, forces this to even increase the cost of the materials and carry out a greater amount of processes and have longer execution times for assembly, assembly and parts, without guaranteeing adequate resistance and waterproof as raised in our invention.

DESCRIPTION OF THE INVENTION The best way to carry out the invention is to design, manufacture and assemble a pre-assembled modular wall for divisions containing: waterproof modular panels (1) which are connected to each other and to the connectors (2) by means of male (3) and female (4) sliding guides, with a thickness ranging between 45 mm and 55 mm and a length between 70 cm. and 1 m., also containing connectors (2) between the "T" joints of the wall divisions that has a configuration of sliding guides to join the wall and at the corner corner joint.

The modular panels (1) are made by extrusion in rigid PVC, ABS and / or Polypropylene being the most used PVC, they have on their sides a configuration with sliding guides male (3) - female (4) that serves to join the other modular panels (1) or to the connectors (2) for divisions of the area with the walls and in the corners, it also has 4 chambers (5) divided by 3 cells (6), being its best design with a thickness between 4 cm to 6 cm and a length of between 60 cm to 100 cm, having these 3 alveoli (6) reduces the risk of opening or deformity of the material due to the weight of the cement; It also has side holes (7) that serve to intercommunicate the chambers (5) that are formed internally to allow the passage of the fluid base material of the wall spaced apart with a distance of 40 cm to 65 cm between centers, these panels ( 1) they have an external grooving (8) and / or a low textured relief (9). You can have a modality that has modular panels (1) reinforced internally with the foot of friends (16) in order to prevent the opening of the panel when it is filled with cement.

It also contains connectors (2) are made of rigid PVC, ABS and / or Polypropylene, they have on their sides a configuration of male (3) - female (4) sliding guides that are used to join the other modular panels (1) for the divisions of the area with the walls and in the corners; characterized by having a configuration in three of its four sides in which they have two female sliding fins (4) configured to allow the sliding of the side formed as male (3) in the panels (1) and in its third side a side male (3) that fits on the fins on the female side (4) of the panels (1). These connectors (2) are made of rigid PVC, ABS and / or Polypropylene and have on their sides a male (3) - female (4) configuration to make a "T" for division of areas to enclose with the walls (1 ) and are not configured differently from those that join the corners of the walls being exactly the same.

MANUFACTURE OF WALLS AND CONNECTOR

For the manufacture of the panels there are five molds in engineering material known as P20 steel, which are named for contamination and are shown in the figure chapter.

• Wall nozzle (Figure 2, 2A and 2B): in this nozzle the modular walls (1) are manufactured by extrusion.

• Wall Calibrator (Figure 3)

• Connector Nozzle (Figure 4 and 4A)

• Connector Calibrator (Figure 5)

These previous ones are shaped like this:

i. Zone of pyramids to break the material, being 4 pyramids that make up the mold being the two sides (10) of equal trapezoidal configuration inclined smaller than those in the middle (1 1) with a trapezoid angle that oscillates between 3 ^or a 7 ^or one of its sides and between 45 ° to 65 ° on its other side; and those of the middle (1 1) of the same trapezoidal configuration with its inclined sides ranging between 3 ^or 7 ^o , with an entry head of between 22 cm and 27 cm; ii. Dice area (12) that is the center and heart of the panel being the negative of the configuration of the wall panel (1) and located in the central part of the mold; iii. Mooring zone (13) which is one or more rectangles shaped to fit around the dice and withstand the pressure exerted by the extruded plastic material therethrough without deforming by temperature that is between 140 ° C to 180 ° C; iv. Lips (14), which are those that originate the external grooving (8) in the wall panel (1) and are located the last mooring (13) at the exit of the material.

These areas are strongly joined together by means of screws that slide through through holes between the entire mold assembly.

It must also have a connector mold with the same mold characteristics for the modular panel. At the end of the material exit through the molds, a calibrator that is the negative of the shape or of the panel (1) or of the connector (2) that generates a vacuum in the newly extruded part of the mold must be guaranteed ensuring that it is not deformed and with water cooling channels that cool the piece to give it its final finish before being cut to the required length.

On-site Assembly and Assembly Process

The Manufacturing Process of the pre-assembled modular wall panel for divisions and the connector for "T" joints of walls and corners must have the following stages: a. Extrusion of plasticized material towards the area of pyramids that break the material with its inclined trapezoidal configuration, forcing the material to go towards the dice; b. Distribution of material in the area of dice (12) holding constant pressure and temperature; forcing the preformed material towards the exit in the middle of the mooring area (13); C. Entrance of the preformed material to the calibrator (15) that generates vacuum and cooling during its passage allowing the material to harden and guarantee its dimensions; d. The panels are cut according to the mentioned dimensions.

IMPORTANT ASPECTS TO CONSIDER DURING ADEQUACY

The process for assembling the pre-assembled modular walls costs the following stages: a) Site preparation; Define: Dimensions, shape and depth of the pool. Make detailed plans of it: plants, cuts and details.

Locate and stake out: It is better to locate the pool in high places than in low places, especially when the water table is high. Staking out is drawing the real outline or perimeter of the pool on the ground, using lime or sand.

DISCOVERY:

Remove the plant material, including trees and roots, existing within the pool area and 50 centimeters outward around it.

LEVELING:

Choose a reference level, with respect to the built housing, which can be the finished floor and based on it, determine the zero level of the pool, which corresponds to the final floor finish of the pool exteriors. Mark the levels on a vertical stake firmly embedded in the ground.

EXCAVATION:

It can be manual or mechanical, it includes the outline of the pool plus 50 cm outwards, space that is required to give space to assemble the structure in PVC. Example: if the pool is 5mx10m, the excavation should be done 6mx1 1m. The excavation is carried out until reaching a depth of 103 cm, from the zero level of the pool. The additional 3 cm are filled with a 3cm poor concrete screed, on which the PVC side wall is placed. And the remaining meter corresponds to the height of the panel.

ABOUT EXCAVATION:

At the bottom of the excavation a 50 cm wide bench is left in contour, the ground continues to be excavated until the depth of the water mirror is completed; that is the depth where the water level reaches. Example: if the pool is wanted at a depth of 1.40 cm. Water mirror, the glass must have a depth of 1.50 cm, The additional 17 cm is 10 cm for free edge and 7 cm for the concrete floor plate with electro-welded mesh. TUNING THE GROUND VESSEL:

It consists of marking the final levels and rectifying the measurements, making the required adjustments manually. If filling is needed, fine, sifted and tightly compacted material with tamper or frog should be used. INSTALLATION OF THE BACKGROUND PIPE: In the deepest part of the pool the bottom pipe is installed, forming a Te with two separate elbows at least 90 cm, to which the wells with anti-scratch grid are connected. The bottom pipe leaves the pool in a single tube, which must reach the independent machine room and be connected there to the water inlet line to the pump.

CONSTRUCTION OF THE SOLADO IN POOR CONCRETE:

The ground bank of the interior contour of the pool must be leveled and taped, manually or with a frog, to be firm. Any filler that is needed should be fine and shaken. On the compacted bench an enlistment of poor concrete of 3 cm thick is made, leaving a minimum setting for one day. This Enlisted is used as a base to assemble the structure or PVC wall of the pool whose measure is generally 1 ms high.

If the terrain is very unstable or the water table is very high and the season is rainy, it may be necessary to build the internal bench in cyclopean concrete, using wooden stretchers for the formwork, refining the upper part so that once the floor is built . (Ground stability tests must be performed to determine). The groundwater in the pool vessel must be evacuated with a bilge pump. Sometimes it may even be necessary to build a well outside the vessel, deeper than this one, to facilitate the drainage of groundwater and to work in a clean excavation. CONSTRUCTION OF INTERNAL POOL TALUD:

It is constructed by splitting the edge of the floor and to the bottom of the pool, keeping the following proportions Vertical: Horizontal 4: 3 or 5: 3, as the case may be or as indicated by the pool plan. If the ground is firm and consolidated, the slope can be done on land and covered with concrete. If the land is poorly consolidated and collapses easily, it is better to build the slope in cyclopean concrete, using stretchers as a formaleta; and sharpen it superficially until it is soft to the touch. b) Enlistment of pre-sized panels (1) and connectors (2); c) Assembling the modular walls by sliding and joining their male sides (3) in the female part (4) between panels (1) and connectors (2); d) Installation of moorings and fittings; ASSEMBLY OF THE PVC STRUCTURE: • Ensure that the bench, the slope and the bottom of the pool are level, smooth and clean, free of filler material, debris, tools and equipment used during construction.

• Consult the pool plan and check dimensions, depth and radii. · Assemble the pool support structure, using the tongue and groove panels 25 cm wide and 1 m long. Each 4 panels insert a post leaving the flat part inwards. Cut a panel to 97 cm, assemble it to the external wall of the post, which is the panel that will be used as a paral, leveling at the lower end. This reinforcement panel is called paral and is placed every 1 ms, that is, every 4 panels goes 1 column and on this goes 1 paral and so on until the fence is finished.

NOTE: The necessary flexibility for arcs and free forms is obtained by opening the panels along with a polisher, always on the outside of the pool and this slot allows you to break the panel to adjust the exact radius.

• When you have finished assembling the panels following the design and shape of the pool, check their level that they are completely plumb and fix them at the top of the coupling point with 1 "self-tapping screw, so that the moored structure remains horizontally Y firm, in the same way the paral is fixed to the post.

NOTE: The stops reinforce the wall and are attached to each post, are inserted into the perimeter ring of concrete that melts external to the vessel, at the base of the wall and is part of the self-supporting structure of the pool.

• Once the entire structure is assembled, check the internal dimensions of the pool, comparing with the approved plan and make the corrections of the case. It is important to verify exactly the size of the armed vessel and respect it, with respect to the original plane there can be no variation because the linner is designed strictly with these measures so that when it is installed it fits perfectly and no creases or wrinkles arise due to measurement variation.

NOTE: When the pool is irregularly shaped, it is very important to check the radii and the length of the arcs of the curved parts and when the exact measurement is straight, the radii of the corners are usually worked in radii of 60 cm preferably. It depends on this that the linner fits perfectly to the vessel, avoiding subsequent arrangements that are more complicated. · SHARPENING: Aim the armed structure with metal and wood profiles, inside and out, so that it retains its firmness and levels. Maintain the propping until the concrete has set and the excavated external part is filled and compacted to the level required for the construction of the platforms. e) Pouring concrete into the chambers (5) of the panels (1).

When the structure has been propped up and it is verified that it is firm, leaded and leveled horizontally, the form is assembled for the outer perimeter ring of concrete, which is 30 cm wide and 20 cm thick. Once this task is completed, the next step is to leave the dead or exact points where the accessories are installed, and then fill the hollow panels with 3000 PSI concrete and melt the perimeter ring, activities that are carried out simultaneously and during a single day of work, so that the concrete is monolithic and the resulting structure is self-supporting. The concrete is prepared in the proportions established for the necessary strength, using fine mixed (maximum crushing size: ¼ "). First the panels and the parales are filled, gently sucking the concrete with a ½" or 3/8 rod ", to avoid empty spaces or air chambers.

APPLICATIONS IN MODULAR CONSTRUCTIONS MODULAR CONSTRUCTIONS: It consists of the following steps: foundation plate, drain installation, column, wall, sill, lintel, hydraulic and electrical installation, cast iron, roof and PVC carpentry. Base plate: Its main function is to give stability to the modular construction that is going to be carried out, by enlisting the land with bases that can be managed in a foundation, with footings at the sites where the international pools column is projected, specifically constructed of 180 kg / cm ² to 240 kg / cm ² with an electro-welded mesh for strength, whose thickness is between 5 cm to 10 cm.

MODULAR CONSTRUCTION AUTO CARRIER.

Wall: Made up of male-female PVC panels and assembled using connector posts, of the same material, which are assembled on the base plate, lifting the walls according to the design to be built, houses, booths, enclosures, machine rooms and all types Modular construction

Installation of drains: The facilities to evacuate all sewage that comes out of bathrooms and kitchen in a housing unit. Partition walls: These are partition panels that are assembled on the PVC post. They are attached perpendicularly to the wall to divide the interior spaces of a construction, whose function apart from supporting the wall divides the environments.

Rails: They are panels at the height of 1 mtrs that are located in the spaces where windows or open spaces go according to the design of the house.

Dinteles: They are panels of height of 0.50 mtrs on the upper part of the window to give auction to the outer wall of the housing unit and allow to handle the tie down strap to support the housing unit cover. Hydraulic and electrical installation: The water and energy connection facilities necessary for a housing unit, which are carried out using the inner cells or holes of the panels or walls before making the casting of the wall. Casting of walls: Concrete 180 kg / cm ² to 240 kg / cm ² , with gravel between 2 cm to 4 cm selected, plant sand, 1 rod between 8 mm to 1 1 mm in each panel, emptied in column and wall , to give greater stability and resistance to the walls of the housing unit. Cover: It is made of light-weight PVC roof tile, which is unloaded onto access profiles where anchoring and support is carried out, according to the slope and design of the roof.

PVC carpentry: PVC doors and windows are installed according to the design chosen and marketed by the companies dedicated to this item.

DESCRIPTION OF THE FIGURES

To complement the description that is being made and in order to help a better understanding of the characteristics of the modular walls and their process by those studying the present application, a preferred example of the realization of this invention is taught, to through the following illustrative figures:

Figure 1 It shows the Isometric drawing of the Wall assembled to the main object connector of this invention, there is a detail of the holes that allow the passage of cement between the panels and in turn between the chambers.

Figure 1 A. It shows a front view Wall assembled to the connector of the previous view allowing to better observe the cameras and the alveoli that compose it and its sliding connection with the connector. Figure 1 B. Front view Extruded wall, grooved detail and surface finish, is a view that shows the moment when the mold panel comes out and the grooving and the final finish are observed. Figure 1 C. Front view Wall in a special modality to prevent the panel from opening due to the weight of the cement and is with the foot of reinforcement friends.

Figure 2. Shows the Isometric view of the complete nozzle where the panel that forms the modular wall comes out.

Figure 2A It shows a view in front nozzle plan revealing the areas that comprise it, especially the detail of the pyramids through which the material enters.

Figure 2B. It shows the front view nozzle with the figure with which the extruded material will come out.

Figure 3. Shows the calibrator that receives the preformed panel above. Figure 4. It shows the Isometric view of the nozzle of the connector that is the complement of union of the walls when it is done you want to place a wall at 90 ° of the initial wall in the form of "T" or for the corners of the construction.

Figure 4A It shows the front view of the connector nozzle where the configuration of the connector sides is observed.

Figure 5. The caliper that receives the preformed connector and gives the end to the piece that is extruded is observed. Finally figures of how applications in modular constructions are attached. COLUMN AND WALL ASSEMBLY FOR EXTERNAL WALLS:

ASSEMBLY OF DIVISORY WALLS ACCORDING TO HOUSING DESIGN:

ASSEMBLY OF ANTEPECHOS AND DINTELES ACCORDING TO HOUSING DESIGN:

COMPLETE WALL CASE OF THE HOUSING UNIT:

PVC COVERED ASSEMBLY OF THE OCCUPATIONAL UNIT WITH CARPENTRY INSTALLATION:

TERMINATION OF THE OCCUPATIONAL UNIT WITH ELECTED FINISHES:

Claims

REIVINDICATORY CHAPTER

1) A pre-assembled modular wall mold for divisions characterized in that it is made of an engineering material known as P20 steel, consisting of the following areas:

a) Zone of pyramids to break the material, 4 pyramids being the ones that make up the mold being the two sides (10) of the same inclined trapezoidal configuration smaller than those in the middle (1 1) with a trapezoid angle that oscillates between 3 ^or 7 ^or one of its sides and between 45 ° to 65 ° on its other side; and those of the middle (1 1) of the same trapezoidal configuration with its inclined sides ranging between 3 ^or 7 ^o , with an entry head of between 22 cm and 27 cm;

b) Zone of dice (12) that are the center and heart of the panel being the negative of the configuration of the wall panel (1) and located in the central part of the mold; c) Mooring area (13) which is one or more rectangles shaped to fit around the dice and withstand the pressure exerted by the extruded plastic material through it without deforming by temperature that is between 140 ° C to 180 ° C ;

d) Lips (14), which are those that originate the external grooving (8) in the wall panel (1) and are located the last mooring (13) at the exit of the material.

These areas are strongly joined together by means of screws that slide through through holes between the entire mold assembly. 2) A connector mold according to claim 1 characterized in that it is made of P20 steel, constituted by the same areas of the mold for the panel, but which is configured exclusively for the figure of the connector (2) that fits with said panel of wall (1), being two of its four sliding sides in the form of female (4) and one in the form of male (3).

3) A gauge for panel or connector mold according to claims 1 and 2, characterized in that it is the negative of the shape or of the panel (1) or of the connector (2) that generates vacuum in the newly extruded part of the mold guaranteeing that does not deform and with some water cooling channels that cool the piece to give it its final finish before being cut to the required length.

4) Manufacturing process of the pre-assembled modular wall panel for divisions and the connector for "T" joints of walls and corner units characterized by the following stages:

a) Extrusion of plasticized material towards the area of pyramids that break the material with its inclined trapezoidal configuration, forcing the material to go towards the dice;

b) Distribution of material in the area of dice (12) maintaining constant pressure and temperature; forcing the preformed material towards the exit in the middle of the mooring area (13); c) Entrance of the preformed material to the calibrator (15) that generates vacuum and cooling during its passage allowing the material to harden and guarantee its dimensions;

d) The panels are cut according to the dimensions.

5) Process for the assembly of pre-assembled modular walls characterized by the following stages:

a) Site preparation;

b) Enlistment of pre-sized panels (1) and connectors (2);

c) Assembling the modular walls by sliding and joining their male sides (3) in the female part (4) between panels (1) and connectors (2);

d) Installation of moorings and fittings; Y

e) Pouring concrete into the chambers (5) of the panels (1).