WO1995034721A1

WO1995034721A1 - Wall element arrangement

Info

Publication number: WO1995034721A1
Application number: PCT/FI1995/000336
Authority: WO
Inventors: Seppo Karimäki
Original assignee: Neste Oy
Priority date: 1994-06-10
Filing date: 1995-06-09
Publication date: 1995-12-21
Also published as: RU2153047C2; EP0766766A1; FI942732A0; HUT77832A; AU2738795A; FI98398B; PL176355B1; PL317648A1; FI98398C; NO965263D0; FI942732A; HU215516B; HU9603412D0; NO965263L; EE9600173A

Abstract

Wall element for a wall structure containing thermal insulations (10) and additional insulations (40) in the form of boards as well as carriers consisting of vertical load-bearing studs (20) which can be at least partly embedded into grooves (11) in thermal insulation board (10). The thermal insulation comprises a board (10) of cellular plastic where at least on its one side are formed vertically oriented laterally spaced grooves (11), into which vertical load-bearing studs (20) of the wall element can be mounted by nailing or in some other such way to vertically oriented mounting ribs (30) located at the same point on the opposite side of thermal insulation board (10). The depth of grooves (11) in the surface of thermal insulation board (10) is chosen so that when embedded against bottom (12) of groove (11), the vertical load-bearing stud (20) will protrude from the surface level of thermal insulation board (10) by a distance equal to the thickness of additional insulation layer (40). The vertical sides of thermal insulation board (10) have grooves (14) and corresponding protrusions (15) to join the thermal insulation boards (10) of adjacent elements with a tongue-and-groove joint.

Description

WALL ELEMENT ARRANGEMENT

The invention concerns a wall element system comprising heat insulations and fire- resistant or acoustic insulations as well as carriers consisting of vertical and horizontal studs.

Especially when building small houses with a wooden structure the conventional building method comprises forming a structural frame on top of a foundation. The frame usually consists of horizontal planks and vertical studs in between, which form the load-bearing structure. The required heat insulating boards are placed between the vertical studs and damp-proofing plastics are fastened inside and wind-proofing boards outside the heat insulations. The wooden frame together with its insulations is covered on its outside surface with an exterior coating and on its inside with interior decoration boards.

This kind of building method requires much handwork. For this reason, an element system has been introduced wherein entire walls are prefabricated at element factories and the walls are joined to one another on the building site. Such elements are usually quite heavy, and hoisting machines are needed to mount the same on the building site. Nor are changes of any kind possible on the building site. This is why such element systems are also in demand which consist of smaller and lighter wall elements which can be easily assembled to make walls of different sizes and wherein changes can easily be made on the building site.

Such a wall element is known, for example, from the Norwegian patent specification 151251. The element according to this specification consists of an insulation material core on both sides of which covering boards are attached by glueing. On the inside of each covering board vertical studs are attached by glueing at equal distances from one another, whereby the vertical studs go into grooves in the insulating material. The vertical studs on opposite sides are at different locations. Elements can be combined side by side and on top of one another in order to form entire walls. Such an element is prefabricated at the factory and it can not be put together from its components on the building site. No changes can be made to the element on the building site. In addition, the element according to the specification does not contain any fire- resistant layer, so such a layer and its supporting structures must be added afterwards as external structural members of the element.

The invention concerns a wall element based on a predesigned thermally insulating board of cellular plastic. Fire resistance is a problem with thermal insulations of cellular plastic, which means that the wall structure preferably also contains fire-resistant layers. Thus, the invention especially concerns a wall element for such a wall structure which contains thermal insulations in the form of boards, additional insulations and carriers consisting of vertical load-bearing studs which can be at least partly embedded in grooves in the thermal insulation. The wall element according to the invention can be preassembled at the element factory or it can be easily assembled on the building site without any special tools. The invention also concerns a wall element system based on such a wall element.

The wall element according to the invention is characterized by the features presented in claim 1. The wall element system according to the invention is characterized by the features presented in claim 6.

In a wall element and wall element system according to the invention the thermal insulation comprises a thermal insulation board of cellular plastic, where at least on one side grooves for vertical load-bearing studs are formed at desired locations and preferably equally spaced. The width of these grooves corresponds with the thickness of the vertical studs so that the vertical studs can be embedded in the grooves. The groove depth is chosen so that when placed against the groove bottom the vertical stud will protrude from the thermal insulation board by a distance equal to the thickness of an additional insulation layer. Thus, a space is formed between the inner surface of the thermal insulation board and each vertical stud and a fire-resistant board is placed in this space. The distance between grooves is chosen so that, for example, a fire-resistant board of standard size, for example, a mineral wool board, fills the space between the thermal insulation board and the vertical studs. The invention is further characterized in that the vertical studs can be mounted into the grooves in the thermal insulation boards by nailing or by attaching in some similar way to vertically oriented ribs located on the side opposite to the thermal insulation board. Screw mounting, for example, may be used just as well instead of nailing.

An advantage of this procedure is that mounting can be done either at the heat insulation factory or it can easily be done later on the building site. Furthermore, as the vertical studs are embedded at least partly in grooves of the thermal insulation boards, the grooves support the vertical studs and prevent them from buckling when loaded. A material thinner than the normal material can thus be used for the vertical studs. In addition, the vertical ribs can easily mount horizontal mounting planks or ribs required for mounting the external cladding so that an air gap remains between the thermal insulation board and the external cladding. On the inside of the element a uniform smooth surface is formed after mounting the fire-resistant board or other additional insulation layer, because the external side surfaces of the vertical studs are at the same level with the fire-resistant board. On this surface it can easily mounted a plastic film or aluminium foil or such acting as a vapour barrier and an inner coating board, because the vertical studs are visible, although in the plane of the surface. In the element according to the invention the additional insulation layer is as dense as possible because the grooves in the thermal insulation boards locate the vertical studs precisely in their proper locations without any measurements.

The wall element system according to the invention is further characterized in that the vertically oriented lateral edges of the thermal insulation boards are shaped so that a tight tongue-and-groove joint is formed when elements are located side by side. One side of each thermal insulation board thus has a groove and the other side has a corresponding protrusion. Hereby a tight and strong joint free from thermal leaks is achieved without any sealants. The bottom edge of the heat insulation board is also preferably provided with an indentation so that it fits tightly into the horizontal plank or other carrying profile located on the foundation.

According to an advantageous embodiment of the invention, the top ends of the vertical studs have an indentation where a horizontal beam at the top edge of the element can be mounted.

According to another embodiment of the invention, the vertical ribs may also function as load-bearing vertical studs. Hereby vertically oriented grooves may be formed also in the external side of the thermal insulation board at locations corresponding to those in the internal side. The groove depth may be chosen so that the vertical studs functioning as vertical ribs protrude from the surface of the thermal insulation board, whereby additional insulation boards can also be placed between the studs. The groove depth may also be chosen so that the vertical studs are embedded entirely into the thermal insulation board on the external side of the insulation board. The thermal insulation board may thus be fire-insulated or sound-insulated on both sides. In this embodiment the number of load- bearing vertical studs may be considerably higher and the material may thus be thinner.

Any shape-permanent insulation material in the form of a board and functioning as thermal insulation may be used as insulation material, if suitable for the purpose as regards its strength. Very suitable materials are cellular plastic products, such as cellular polystyrene (EPS or XPS), and polyurethanes and cellular plastics containing phenolfor- maldehyde resin. Likewise, any material in the form of a board and with adequate fire- resisting properties can be used as the fire-resistant layer forming the additional insulation. Mineral wool, for example, is a suitable material. Heavy mineral wool, for example, is a suitable material in terms of acoustic engineering. The additional insulation layer is preferably in board form, but a material to be blown in place can also be applied instead of a board.

Wood and plywood are advantageous materials for the load-bearing parts. Plastic profiles which may be either fibre-reinforced or non-reinforced, may also be used as material for the vertical load-bearing studs, the vertical ribs and the horizontal ribs. Metals, such as steel or aluminium profiles, may of course be chosen as material.

With the present invention an exactly dimensioned wall element system is thus achieved, which allows assembling the wall element from its components on the building site regardless of prevailing conditions. The elements may also be assembled at the element factory. The wall element according to the invention is light and easy to mount without any special tools and hoisting equipment. The structure is good in terms of energy technology, because no cold bridges are formed between the elements, and it is structural¬ ly strong, because the vertical load-bearing studs are embedded in grooves of the thermal insulation boards, whereby buckling risks are eliminated. The wall element according to the invention is also structurally simple and thus also attractive as regards its price, and no separate windscreen layers are needed.

The invention is described in the following referring to the appended figures, wherein

Figures 1 and 2 show sectional views from the side and from above and exploded views of main components in a wall element system according to the invention;

Figure 3 shows a view from above of two wall elements according to Figure 2 with the components fitted and mounted together;

Figure 4 shows a view from above of two modified wall elements according to Figure 3 with the components fitted and mounted together;

Figure 5 shows a view from above of a wall element having a fire-resistant layer or some other additional insulation layer on either side;

Figure 6 shows a modification of the wall element shown in Figure 5; and

Figure 7 shows a perspective sectional view of a whole wall element.

Figures 1 and 2 show a thermal insulation board 10, vertical studs 20, vertical ribs 30 and a fire-resistant board 40 separate from each other. Vertically oriented grooves 11 for vertical studs 20 are formed in the thermal insulation board 10. The width of grooves 11 corresponds with the thickness of vertical studs 20, whereby vertical studs 20 can be embedded in grooves 11. The depth of grooves 11 is chosen so that when pressed against bottom 12 of groove 11, stud 20 will protrude from the surface of thermal insulation board 10 by a distance equal to the thickness of fire-resistant board 40. Furthermore, a protrusion 13 is formed in one vertical side of thermal insulation board 10 and correspondingly a groove 14 of similar shape is formed in the other vertical side, so that a tongue-and-groove joint is possible between adjacent elements. Vertical studs 20 and vertical ribs 30 are fastened through thermal insulation board 10 with nails, screws or other such fasteners 31.

Figure 3 shows a view from above of two adjacent wall elements with their components located and fastened in place. The figure also shows fire-resistant boards 40 fitting between vertical studs 20 and entirely filling the space between vertical studs 20 and thermal insulation board 10, whereby surface 41 of fire-resistant board 40 is in the same plane as the surface 21 of vertical studs 20. Reference number 32 indicates a horizontal plank or rib fastened to vertical ribs 30 for fastening an external wall cladding to the wall after the elements are mounted.

Figure 4 is similar to the embodiment shown in Figure 3 with the exception that thermal insulation board 10 is also provided on its external side with vertically oriented grooves 15, into which vertical ribs 30 are embedded.

Figure 5 shows a view from above of a wall element where the vertical ribs on the external side of the element are replaced with vertical studs 20 and where fire-resistant boards 40 are located on both sides of thermal insulation board 10.

Figure 6 is similar to Figure 5 with the exception that vertical studs 20 on the external side of the wall element are also embedded entirely into thermal insulation board 10. On the external side of the wall element attached to thermal insulation board 10 it is located a gypsum board 41 fastened to the structure with nails 31 by nailing through vertical ribs 42, board 41, vertical studs 20 and thermal insulation board 10 into vertical studs 20 on the opposite side of the vertical studs 20. A wall structure additionally insulated on both sides is thus achieved.

Figure 7 shows a perspective view and partly sectional view of the wall element mounted on top of a horizontal plank 2 resting on foundation 1. The top edge of the element has a horizontal plank 3, which is fastened to indentations (not shown) in the top ends of vertical studs 20 embedded partly into thermal insulation board 10. According to th figure, the top side of the element is covered by a horizontal board 4. The figure furthe shows fire-resistant boards 40 functioning as additional insulation and fastened betwee thermal insulation boards 10 and vertical studs 20 so that their external surface on th internal wall surface is flush with the surface of vertical studs 20. Reference number 1 indicates the seam between two adjacent thermal insulation boards 10. A vapour-proo layer 50 is located on additional insulation board 40 and an internal coating board 60 i located on layer 50. In addition, the figure also shows electric cables 70 located i additional insulation layer 40 and leading to socket 71 in internal coating board 60.

Claims

Claims:

1. Wall element for a wall structure containing thermal insulations (10) and addition insulations (40) in the form of boards as well as carriers consisting of vertical loa bearing studs (20) which can be embedded at least partly into grooves (11) in therm insulation board (10), characterized in that the thermal insulation comprises a cellul plastic board (10) where at least on one side vertically oriented grooves (11) are forme laterally spaced, into which grooves vertical load-bearing studs (20) of the wall eleme can be mounted by nailing or in some other such way to vertically oriented mounting rib (30) located at the same point on the opposite side of thermal insulation board (10), th the depth of grooves (11) in the surface of thermal insulation board (10) is chosen so th when embedded against bottom (12) of groove (11), vertical load-bearing stud (20) wi protrude from the surface level of thermal insulation board (10) by a distance equal to th thickness of additional insulation board (40), and that the vertical sides of therm insulation board (10) have grooves (14) and corresponding protrusions (15) to join th thermal insulation boards (10) of adjacent elements with a tongue-and-groove joint.

2. Wall element according to claim 1, characterized in that on its both sides therma insulation board (10) has similarly located vertically oriented and laterally spaced groove (11, 15) for the said vertical load-bearing studs (20) and for the said mounting ribs (30)

3. Wall element according to claim 1 or 2, characterized in that the depth of groove (15) for the said mounting rib (30) is chosen so that the outer surface of mounting rib (30 protrudes from thermal insulation board (10) by a distance equal to the thickness o additional insulation board (40), whereby additional insulation (40) can be placed on bot sides of thermal insulation board (10).

4. Wall element according to any claim 1 - 3, characterized in that the bottom edge o thermal insulation board (10) has an indentation (16) corresponding to the shape of th wall foundation (1) or the shape of a horizontal plank or carrying profile (2) located o the foundation.

5. Wall element system according to any claim 1 - 4, characterized in that the materi of the said thermal insulation board (10) is cellular plastic, for example, polystyren polyurethane or phenolformaldehyde resin.

6. Wall element system containing thermal insulations (10) and additional insulations (4 in the form of boards as well as carriers consisting of laterally spaced vertical loa bearing studs (20), which can be embedded into grooves (11) in thermal insulation boar (10), and optionally of horizontal planks (3) supported on vertical load-bearing studs (20 characterized in that

(a) vertical load-bearing studs (20) are mounted in grooves (11) in the surface of therm insulation board (10) by nailing or in some similar way to vertically oriented mountin ribs (30) located at the same point on the opposite side of thermal insulation board (10

(b) the depth of grooves (11) in the surface of thermal insulation board (10) and the widt of vertical load-bearing stud (20) are chosen so that when embedded against bottom (1 of groove (11), vertical load-bearing stud (20) will protrude from the surface level thermal insulation board (10) by a distance equal to the thickness of additional insulatio layer (40),

(c) the vertical sides of thermal insulation board (10) have grooves (14) and correspondin protrusions (15) to join thermal insulation boards (10) with a tongue-and-groove joint.

7. Wall element system according to claim 6, characterized in that an indentation (21 for mounting horizontal supports/ braces (3) is formed in the top end of vertical loa bearing studs (20).

8. Wall element system according to any above claim 6 - 7, characterized in that it provided with vertically spaced horizontally oriented ribs (32) which are fastened to t said vertical mounting ribs (30) by nailing or in some other such way and which functio as mounts for mounting an external wall cladding at air-gap distance from therm insulation board (10).

9. Wall element system according to any foregoing claim characterized in that the sai mounting ribs (30) are entirely or partly embedded in vertically oriented grooves (15) thermal insulation board (10).

10. Wall element system according to claim 9, characterized in that the said mounti ribs (30) also function as vertical load-bearing studs and they are embedded in groov

(15) in thermal insulation board (10), the depth of which is chosen so that the out surface of mounting ribs (30) protrudes from thermal insulation board (10) by a distan equal to the thickness of additional insulation layer (40), whereby additional insulati boards, for example, fire-resistant boards or sound insulation boards (40) can be plac on both sides of thermal insulation board (10).

11. Wall element system according to claim 9, characterized in that it contains vertic studs (20) also on the external side of the wall element entirely embedded into groov (15) in thermal insulation board (10), that a fire-resistant board (41) is mounted to t external side of thermal insulation board (10) by nailing through mounting ribs (42), fir resistant board (41), vertical studs (20) and thermal insulation board (10) to vertical loa bearing studs (20) located on the opposite side.

12. Wall element system according to any above claim 6 - 11, characterized in that t said additional insulation is a mineral wool board, a gypsum board or blown- in miner wool.