WO2017055669A1 - Método de fabricación de panel de pared o techo con instalaciones incluidas, paredes o techos prefabricados por dicho método y uniones entre paneles pared y techo - Google Patents
Método de fabricación de panel de pared o techo con instalaciones incluidas, paredes o techos prefabricados por dicho método y uniones entre paneles pared y techo Download PDFInfo
- Publication number
- WO2017055669A1 WO2017055669A1 PCT/ES2016/070689 ES2016070689W WO2017055669A1 WO 2017055669 A1 WO2017055669 A1 WO 2017055669A1 ES 2016070689 W ES2016070689 W ES 2016070689W WO 2017055669 A1 WO2017055669 A1 WO 2017055669A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- wall
- ceiling
- mold
- frame
- polyurethane
- Prior art date
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/776—Walls, e.g. building panels
Definitions
- the object of this invention is the design of a product that suits a construction system that meets these needs, that is, a type of wall that can be manufactured in a plant and specific to the design and with the openings and installation of services requested by the client. That, in turn, is composed of a light wall, but with a solid and rigid core, and whose exterior finish is similar to the traditional construction for the purposes of sight and touch. And that it contains the structural beams inside the prefabricated wall, that is to say that it is self-supporting, which avoids having to perform them on site.
- the construction system is based on the manufacture of entire walls in a manufacturing plant, which will then be mounted at the construction site without the need for any previous structure since the beams that give rigidity to the structure are included in the wall.
- the wall is composed of a rigid core that is contained by a Frame that limits the outer edges of the walls, as well as the internal edges intended for the placement of doors or windows. Adhered to the rigid core are layers of external and internal termination.
- finishing layers can be obtained by fixing plates to the core or by applying a layer of cement that achieves a similar finish to the traditional construction, either in sight or touch.
- the wall is finished in the factory, it is transported to the construction site where it is anchored to the floor and joined together. Once joined the walls proceed to roof and waterproof them.
- water collectors covering the outer surface thereof can be incorporated. In this way the roof surface is transformed into a large solar collector.
- a first aspect of the invention relates to:
- a method for manufacturing walls characterized in that they are manufactured to the needs and in the factory, with reticular structure, internal beams and internal frames (such as for windows and doors) within them, all within a peripheral frame which is placed inside a mold that resists considerable pressures and into which polyurethane or other similar substance is injected and expanded, which is distinguished by forming a thermal insulation core that provides mechanical resistance and thermal and acoustic insulation at the same time, possessing within the space contained within the framework that all electrical, air conditioning, water, sanitary in general, pipelines and other services that may be required were placed in the mold, where there is also a metal, synthetic, fiber mesh, or other material, attached to the polyurethane or to the outer frame that delimits the wall, by a layer of polyurea or by clips, screws or other mechanical attachment that join the mesh either to the polyurethane or to the wall frame - which can be wood, aluminum, ferrous metals or other mechanically resistant substances - where an external and / or internal roof covering can be projected on that mesh so supported
- the walls can be manufactured according to the needs and in the factory, with internal beams and internal frames (such as for windows and doors) inside them, all within a peripheral framework that is placed inside a mold that resists considerable pressures and within which polyurethane or other similar substance is injected and expanded, which is further distinguished by forming a core that provides mechanical resistance and thermal and acoustic insulation at the same time, where that mechanical resistance of the insulating element is additional to the provided by the other components of the wall, containing within the space defined by the framework or frame that is placed in the mold all electrical, air conditioning, water, sanitary in general, pipelines and other services that may be required.
- the metallic, synthetic, fiber, or other material mesh in addition to being able to be placed by clips, screws, etc., to the frame or wall frame, or glued with polyurea or similar to the polyurethane core can have a mesh metal inside, outside, or both.
- Both the inner and / or outer meshes and the internal and external panels or terminations can be applied to the wall after it has been demoulded.
- the outer layer and / or the inner layer can comprise bricks of various designs, stones or other similar ones, including standard bricks, which have been applied inside or outside the mold, being that when it is inside the same pressure of the polyurethane expanding it filters through the bricks and provides the union of the same with each other and the rest of the wall (that is to say the polyurethane core or similar), thus providing a multilayer wall of thermal and acoustic insulation that contributes to the structural rigidity of the whole , where one of those layers, or both if it is decided to do so on both the external and internal side, is a standard brick wall but with a multilayer wall attached (or between both layers of bricks, if it is decided to do so) and with the which was built together, thus providing a prefabricated structure that is the conjunction of the traditional structure and the light structure with modern thermo / acoustic layer, and with the aggregate to have contents in its thickness to all services: electrical, sanitary, ventilation, heating, etc.
- a second aspect of the invention relates to a wall manufactured essentially by the method described above, but which will be used as a ceiling, where at the bottom of the mold, that is to say what will be the outer face, manufacturing has been placed a layer of tiles of any design and material.
- a panel of waterproof material, resistant to ultraviolet rays can be placed to prevent its degradation in the sun's rays, and where the waterproof joint or joint between panels Adjacent is made of polyurea or similar material, which will also be specific so as not to degrade with ultraviolet radiation, and adding said polyurea or similar additional structural strength to the ceiling by rigidly joining the different panels.
- a solar heating panel can be placed which is connected to the pipes included in the polyurethane core.
- an interior frame can be placed to provide a window, but in this case it will serve to pass a specific and tailored duct, either ventilation, heating / cooling, or a chimney, or any other duct that It is useful, and where the joint between said duct and the adjacent panel (s) will be waterproofed by polyurea resin or the like, which will be specific to resist solar ultraviolet radiation.
- the prefabricated wall when it has all its layers, can be composed, from the outside to the inside of:
- both the inner layer and especially the outer layer can be a brick wall where the binding element is the same polyurethane that forms the thermal / acoustic layer, and which in the same action of forming the thermal / acoustic layer has leaked between the bricks, setting them together and thus sticking them to the core.
- the wall made of layers can be composed only of two hydrophobic outer sheets of rigid resin such as polyurea or similar, or of the plastic, synthetic, or similar membrane style that is adhered to the core in the polyurethane expansion process, and a thermo layer polyurethane insulation or similar contained between the two rigid resin layers, which polyurethane layer may or may not contain services, facilities, pipes, etc.
- the wall may be surrounded and contained by a peripheral metal frame or other rigid material, and said wall has been formed and set in a mold formed by a frame comprising a metal frame or other rigid material that forms its periphery and to which the mold doors are attached, and thus the wall frame and the mold frame form an internal frame and an external frame.
- the fabricated wall can have the pipes inside the socket, or failing that by the top of the wall, either on the inner edge or on the outer edge, as illustrated in the specification, or even inside the ceiling.
- the joints of the various pipes that go through the ceiling and / or the walls can be resolved either internally or externally to the wall and / or ceiling, or by ducts or spaces formed within the wall, or inside the ceiling, or both, and by means of threads, welds, microsoldaduras, microfusión, assembly to pressure, or any other.)
- the union of the roof pipes with the pipes in the wall is made by an enlarged cavity or canalization at the end of the roof just where it joins the wall, and a similar inlet on the upper end of the vertical wall canalization, such that the enlarged ceiling canalization is just above the enlarged canalization of the wall, thus forming a kind of duct, and where a molding disassembles able at an angle closes the duct thus formed by both widenings from the inner side of the wall-ceiling angle, this molding being
- the connection of the roof pipes with the pipes in the wall is carried out by means of an enlarged cavity or canalization at the end of the ceiling just where it joins the wall, and a similar widening on the inner side of the vertical wall pipe, such that the enlarged roof pipe is just next to the enlarged wall pipe, thus forming a kind of duct, and where a removable and angled molding, closes the duct thus formed by both widening from the inner side of the wall-ceiling angle, that molding being perfectly waterproofed and applied either to the inner side panel, to the polyurethane core, to the ceiling or wall delimiting frame, or to any other part of the themselves, ensuring total tightness but at the same time with access to the pipeline if necessary.
- connection of the pipes can be made by the angle formed by the top part of the ceiling and the wall.
- the connection of the roof pipes with the pipes in the wall is carried out by means of an enlarged cavity or canalization in the ceiling just where it joins the wall, and a similar recess on the upper end of the vertical wall canalization, such that the enlarged canalization of the ceiling is just above the enlarged canalization of the wall, thus forming a kind of duct, and where a removable angled molding closes the duct thus formed by both widenings from the inner side of the wall-ceiling angle, that molding being perfectly waterproofed and applied either to the inner side panel, over the polyurethane core , on the delimiting frame of the ceiling and that of the wall, or on any other part thereof, ensuring total tightness but at your Once with access to the pipeline if necessary.
- the ceiling and wall panels can be fixed in such a way that the roof support on the wall does not cover the entire thickness of it, but only as far as the channeling of the vertical wall appears, and in such a way that both the channeling of the wall and that of the ceiling do not need widening, since the space is externally delimited by an angled molding , removable but perfectly waterproofed, that closes and delimits the duct thus formed, and in this way a space is generated by which to make the connections, as well as the transport of electrical cables or similar conduits.
- This space or duct is then covered by a sheet metal molding, another suitable material polymer.
- the innovation consists in the manufacture of an entire wall or fraction, limited by an outer frame (87, 99, 109, 112, 121, 242, 347, 364, 372) that contains the wall and by inner frames that contain the openings. Inside it has a rigid core that contains the electrical and sanitary installation and other required services, in addition to structural beams.
- the rigid core is coated with an outer and inner layer, said rigid core being at the same time the thermal and acoustic insulation.
- Frame Frame is defined, illustrated in the fjError! The origin of the reference is not found, to the metal or wooden structure or any type of material with similar mechanical characteristics, which fulfills the function of limiting the wall and containing the rigid core (thermal and acoustic insulation) of the same, as well as structural and service components.
- the frame is composed of the outer frame (87, 99, 109, 112, 121, 242, 347, 364, 372) and the inner frame (5).
- the outer frame (87, 99, 109, 112, 121, 242, 347, 364, 372) is the frame that borders the roof (1), floor (3) or other wall (2).
- the inner frame (5) is the frame that borders an opening of the door or window type.
- Structural profile (4) It is a profile or spout of sheet metal or wood or any other material that can be used to add structural resistance to the wall, that is attached to the frame and that are immersed in the polyurethane core in order to increase the structural rigidity of the wall as well as acting as a support for the window frames.
- the framework illustrated in the fjError! The origin of the reference is not found, it is composed of the exterior and interior frames and all the services to be included in the wall including the electrical installation (6,7, 8) and sanitary and other services, as well as the reinforcements structural (4) and internal frames for openings (5).
- the already molded wall is made up of frame, of the panels to be placed, or of the coating layers that have been applied manually or through machines and that act as coating layers and protection of the solid core, and of the solid core and any other type of service that you want to include within the core of the wall.
- the electrical and sanitary services as well as any other type of service that you want to incorporate as heating, water collectors, gas tanks, television wiring, and any other type of service that you want to use within the construction, can be incorporated into Some of the walls.
- the shape of the outer frame where services are to be transported has a fold that generates a duct (wiring duct illustrated in the error! The origin of the reference is not found.) Used to transport electrical cables or other services along the walls.
- the cables and services will be carried by the outer frame of the floor - wall joint or by the frame exterior of the ceiling wall joint. At the end of the pipes, the cables are covered by a socket (9).
- the pipe (6) can be connected to the roof pipes through a connection outside the house or inside, and which are detailed below: Pipe Connection: Roof with External Wall
- the ceiling and wall panels can be fixed according to what is shown in the fjError! The origin of the reference is not found, and the fj Error! The origin of the reference is not found.
- a space 71 is generated by which to make the connections, as well as the transport of electrical cables or similar conduits.
- This space 71 is then covered by a molding 811, 912, 1012, 1111, 125 of sheet metal according to the fjError! The origin of the reference is not found.
- the ceiling panels can be joined using an internal wall as a support base. This connection can be made at the level of the internal wall (Interior Method), or by supporting them on the wall (External Method). Interior Method
- Figure 1 shows an electrical connection for joining ceiling panels to a level interior wall.
- an omega plate 113
- the Omega Sheet is fixed to the outer frame of the wall by means of fixing elements.
- the roof panels are joined to the Omega Sheet by means of fasteners (113,1110) in the case of a level joint.
- the joint is waterproofed by polyurea (111), or some product with similar characteristics. After the waterproofing is done, the Exterior Finishing Mold (1111) is placed.
- Exterior Method Figure 2 shows an electrical connection for joining roof panels to an interior wall supporting them.
- the roof panels (122) rest on the outer frame of the wall (121) and are joined by fixing angles (126), generating a space between both panels that allows the connection of services from the roof of the construction.
- This space is covered with an External Coating for Pipework (125) which is then waterproofed with a layer of polyurea or similar material (123) to be covered later with an External Termination Mold (1211).
- the Exterior Termination Moldings represented by items (1111) in Figure 1 and (1211) in Figure 12 may be replaced by terminations made of the same material of the outer covering layers of the panel if required.
- the panel has an inner core of rigid polyurethane or other similar material that has similar thermal and mechanical properties, and two layers of coating (exterior and interior).
- the composition of the outer and inner layers may change depending on the termination specified for the wall.
- the expanded polyurethane inner core (164) provides rigidity, as well as thermal and acoustic insulation.
- the width of the layer is usually about three to thirty centimeters, although this is basically at the request of the client.
- the wall can be self-supporting, that is, it does not require the construction of beams in place to hurl them since the beams are immersed in the polyurethane core.
- the system has a rigid core without air chambers or non-rigid components such as glass wool or expanded polystyrene, which are frequently used as fillers between the inner and outer wall.
- the rigid polyurethane core gives greater structural rigidity - and even more so if it is coated with polyurea - as well as better thermal and acoustic properties.
- each panel has one (in case of leaving one side of the core
- This layer can be made of a single material that is placed in the mold during the manufacturing process (that is, inside the press mold), or it can be composed of different sub-layers that adhere to the inner core once the panel has been removed from the mold.
- the cement coating layer (167) can be applied to both the outer and inner sides of the wall, and fulfills the function of termination, as well as that of generating stiffness.
- the width of the layer could range from a few millimeters to several centimeters thick. If the traditional cement is applied several millimeters thick, it must be attached to the panel by means of a fastening mesh (168) attached to it. If the cement layer is a few millimeters, it is possible to apply the product directly on the polyurethane core without the need to have the clamping mesh 572, 168.
- the fastening mesh 572, 168 can be metallic or plastic or of any other material that It fulfills the function of fixing to cement, and aims to achieve the fixation of the outer layer of cement (or simile) to the rigid core.
- Figure 8 shows the anchoring of the support clamp mesh 572, 168.
- the 572, 168 support mesh provides structural rigidity. For this reason the size of the lattice, as well as the thickness of the wires or threads are variable depending on the desired structural rigidity, as well as impact resistance and even safety reasons.
- the clamping mesh 572, 168 will be adhered by an adhesive material65 Error!
- an adhesive material65 Error The origin of the reference is not found. such as polyurea or similar, or mechanically attached to the core or frame through clips, screws or the like.
- the polyurea is projected as if it were a painting.
- Figure 9 shows the projection of polyurea on the support mesh 572, 168.
- the polyurea has the function of adhering the support mesh where the cement is applied to the polyurethane core, as well as generating an impermeable layer to protect the core from moisture.
- the thickness of the layer is usually one to five millimeters.
- the Frame is finished without cover plates, they can be attached to the polyurethane core (or to the peripheral frame) after the wall has been unmold.
- the plates can be adhered by means of some adhesive element or through some fastening element such as screws or similar. Coating layer with bricks, stones or similar elements.
- exterior cladding bricks, stones, ceramics, tiles or similar materials that can be placed on the floor of the mold and that will remain attached to the polyurethane core during the process of expansion of the same.
- the pressure causes the polyurethane to seep between the bricks by joining them and replacing the cement.
- Figure 3 shows a side wall section with an outer covering layer made of bricks. Coating layer with ceramic coating or similar
- the Polyurea Sandwich Panel or hydrophobic membrane shown in the fjError! The origin of the reference is not found, it is a simple version of the wall or ceiling panel that can be used in the wall of the invention, as well as in different types of applications in addition to those of the invention.
- This panel has an outer layer of Polyurea or some hydrophobic membrane either plastic, synthetic or similar, which can range from lmm to 10mm that is applied, or is stuck in the process of expanding the polyurethane on a rigid core of expanded polyurethane, polystyrene or some other similar material that can range from lcm to 40cm thick .
- the application of the polyurea can be carried out manually through a gun and the necessary equipment for this purpose, or through a manufacturing line where the polyurea is applied to the solid core continuously.
- the polyurea sandwich panel or hydrophobic membrane and polyurethane is an innovative product that is not on the market today.
- the anchoring of the walls will be carried out on a conventional concrete slab to be sized according to the structural requirements of the building.
- the plate may contain the electrical and sanitary services required by the design of the building.
- Mold It is a robust mold in itself, that supports the metal side plates of the frame where the panel will be manufactured and that has sheet metal caps with structural reinforcements to contain the high pressures generated by the expansion of the polyurethane inside the frame.
- the fjError! The origin of the reference is not found.
- Figure 19A shows a mold 173 that has greater depth for making brick-terminated walls, stones, or similar elements. The fjError! The origin of the reference is not found. Error! The origin of the reference is not found.
- Figure 17 represents a mold 173 where a block 171 of bricks and a prefabricated plate 172 are introduced to form a panel.
- Figure 4 shows a mold 201 of 6x3m with sliding cover 203 for full wall manufacturing.
- the first step in the manufacture of the wall is the placement of these inside the mold, thus remaining at the bottom of it. against the back cover.
- Another option is to mix the cement and place it on the floor of the mold, wait for it to set and then make the reinforcement of the frame on this layer.
- the polyurethane is adhered to the cement layer that was placed on the floor of the mold.
- both layers of coating are finished with prefabricated plates, then the first layer is placed on the floor, that is, at the bottom of the Mold, and another as a cover once the Frame is finished.
- the outer frame is assembled, which is carried out on the already placed plates.
- the outer frame of the wall will be assembled directly on the floor of the mold as shown in the fiError! The origin of the reference is not found.
- the outer frame profiles are joined together by rivets, by insert, by welding or some similar system.
- the inner frame is placed according to the design of the wall and the location of the openings that the wall to be manufactured will contain.
- the inner frame is fastened by screws to pipes of wood or beams of wood or some other type of material that fulfills the function of fastening the opening to the inner frame and that are firm to the outer frame. In this way, the places where the openings are to be placed are not covered with the polyurethane core.
- Figure 5 shows the assembly of the inner frame 231 inside the mold.
- the upper face of the wall is covered with plates, they must be placed as a cover of the Frame before closing the Mold and piercing them through the holes in the cover of the Mold.
- the perforations will be used for the injection of the polyurethane or the material to be used in the inner core, and then they will be covered in the final termination of the wall.
- the cover of the Mold is fixed by means of mechanical elements to contain the increase in pressure due to the expansion generated in the reaction by mixing the polyurethane components (if this is the core material).
- the cover of the Mold contains small holes of about 5mm in diameter (or larger), spaced approximately one meter, through them the cover of the Frame is drilled to reach the inside of the same.
- the polyurethane is injected in order to achieve the necessary density (between 40 and 50kg / m 3 depending on the product to be used and the purpose to be obtained).
- the polyurethane injection is done through a mixing machine of its two essential components (a polyol and the TDI) and an injection gun.
- the injection can be done manually by injecting one hole at a time, or in a way automated with an injection element that can inject into multiple holes at the same time.
- Figure 7 shows the injection of polyurethane through the cover 224 of the mold through the frame manually.
- the first thing to do is open the top cover of the Mold. Then the outer frame of the Mold is disassembled in contact with the outer frame of the wall. When disassembling the outer frame of the Mold, the wall is able to be removed from it.
- the wall is going to have a layer of cement coating, it is applied once the wall has been demoulded.
- the first step is the fixation of the fastening mesh by means of clips, screws, or some similar method either polyurethane core or to the frame by means of fasteners that can cross the sheet metal or wood of the frame.
- the next step is to coat the wall with cement.
- the process can be done through manual application or through machines that automate the system.
- the cement can have varied proportions of cement itself, lime, sand, additives, etc., each with its own particle size so as to achieve a relatively rough or at least rough finish, or a very smooth finish of the "portland type"mirror".
- Cement can have in its mixture a dye that makes this layer already have its intrinsic color, saving us many times another finish or a final paint. Thus, the wall could already leave the factory “painted” in its final color, with great savings in labor and raw materials.
- the figural shows the application of the Cement Coating Layer 167 manually.
- the figure shows the finished Wall panel with Cement Coating layer 167.
- the figural2 shows a ceramic coating on cement and mesh.
- FIG. 3 shows the Welding of the Outer Frame 87, 99, 109, 112, 121, 242, 347, 364, 372 of two panels.
- FIG 33 shows the anchoring of the walls to the floor.
- the walls will be fixed to the floor according to the detail R of the fiError! The origin of the reference is not found, as shown below.
- the anchoring is carried out by means of perforated ground anchoring angles 331 which are fixed by screws to the floor and to the sheet metal frames of the walls.
- the joints of the anchoring angles to the wall frame can be reinforced by welding.
- the rail facilitates the precise placement and assembly, and also the precision in the joints between wall and wall, being that they are embedded in the same rail. In turn, it makes assembly faster and protects the elements from the bottom edge of the wall, making the assembly more robust.
- the U can be on the floor or buried in the stalls.
- Fig. 4 shows an anchoring scheme to the floor with a U-junction attached to the floor.
- the frames of the walls can also have different types of geometry in order to generate a male and female socket on the sides of the frame, which encastulate each other and that can be reinforced either by welding (354) or through fasteners (353) Or simply by the pressure generated male-female mechanical insert.
- Figure 5 shows wall panel joints with frames with insert geometry.
- FIG. 3 Another option to join the walls is to use frames with rectangular geometry and make the union by means of a joining plate (365) that is attached to the outer frame of both panels by screws or welding, and that additionally provides extra protection against the elements, thing which is particularly useful for being junction points.
- the figure shows a top view of joining walls with joining plate.
- FIG. 17 shows an example of welded joint between wall and ceiling panel.
- Figure 18 shows an example of Structural Welded Joint between angled walls Structural Joints between Roof and Roof Panels
- Figure 37 shows the joining of roof panels that use a structural beam to make the joining of the same without the presence of a support wall. These types of joints are used when the total length of the roof panel is not sufficient to cover the entire length of the roof, requiring an intermediate beam to support the joint of two roof panels.
- Figure 19 is a side view showing the joining of roof panels at the structural beam level.
- the joints are waterproofed by means of the application of polyurea or any type of material that fulfills the function of sealing and waterproofing them. Then the aesthetic termination of the joint is carried out by means of sheet moldings that are adhered by screws or some adhesive material, or placed under pressure by means of the fitting with the frame, or simply by applying a coating layer on the structural joint, usually of the same material than the coating layer of the panel.
- Termination Joints It is also possible to place moldings and then cover them with the same material as the exterior walls. These types of unions are called Termination Joints.
- the molding may be made of sheet metal or of any material that fulfills the function of covering the structural joints.
- Figure 20 is a top view of junction between Roof panels and side walls.
- Figure 21 is detail AB of Figure 20 which shows a top view of the end of the molding in the corner.
- Another way of performing the wall-to-wall termination at an angle is by placing the sheet metal molding or similar material as illustrated in Figure 42, to then fill the cavity generated by the molding with the same material as the panel covering layer, and then remove the molding once the filling has set. This way you get a termination in the union of the same material as the coating layer.
- FIG. 22 shows a Termination Union scheme for joints between Wall Panels.
- Termination Union For Exterior Coating with Cement On the walls with exterior cement coating, the Termination Joints can be made with cement.
- Termination Joints between Ceiling - Wall and Ceiling - Ceiling can be made using moldings that are screwed to the outer frame of the panel or by direct coating of the same material as the coating layer applied on the joint.
- Figure 1 shows an electrical connection for joining roof panels on an interior wall at level-item (1111) an electrical connection to join ceiling panels to an interior wall supporting them - item (1211)
- the outer moldings can be replaced by finishes made in the same material of the outer covering layer of the panel if required.
- Figure 47A shows a schematic plan of the house.
- Figures 47B-47F represent different perspectives of the housing scheme shown in Figure 47A.
- Figures 48 and 49 show the detail of the pipes for the electrical service to be installed on the ceiling panels.
- the dark layer of the roof panel represents the outer layer of the panel that can be of various materials, including Polyurea, Cement, M DF, Plaster, OSB, Chipboard of various types, Corrugated or Smooth Metals, Cementitious Plates, Various Resins, Plates combined (marbled or not) of resins and ground minerals, stone plates (marble and others).
- polyurea will be used as an external plate and plaster as an internal plate.
- FIG. 48 The panel marked with the black circle in Figure 48 has hidden the polyurea outer covering plate for illustrative purposes in order to show the pipes of the electrical service inside the ceiling panel (the same has been done with the others roof panels that do not have the dark coating layer).
- Figure 48 shows the perspective with detail of pipes in techose according to the rear view.
- Figure 49 shows the perspective with detail of pipes in techose according to the front view.
- Figures 50A-50B show the perspective of the floorless project showing the different wall panels to be manufactured and assembled. Each Arrow points to a different Wall Panel.
- Figures 51A-51C show a plant and sections of the house.
- Figures 52A-52D show views of the facades of the house: Figure 52A a front view, Figure 52B a rear view, Figure 52C a right side and Figure 52D a left side.
- Figures 53A-53F show details of joints between panels of the house or house 471.
- Figure 53 shows an exterior wall and ceiling connection with parapet.
- Figure 53B shows an exterior wall and roof joint with eave.
- Figure 53E is a section seen from above showing a joint of angled wall panels with overlapping panels.
- Figure 53F shows a pipeline for services.
- Figure 54A shows an exploded view of a panel where the components can be seen: polyurea layer 541, sturdy structure 542, polyurethane core 543 and gypsum board 544.
- polyurea layer 541, sturdy structure 542, polyurethane core 543 and gypsum board 544 Some of the materials that can be used in the outer and inner plates are: Polyurea, Cement, MDF, Plaster, OSB, Chipboard of various types, Corrugated or Smooth Metals, Cementitious Plates, Various Resins, Combined Plates (marbled or not) of resins and ground minerals, stone plates (marble and others), solar panel (external roof plate) ground minerals, stone plates (marble and others).
- Figure 54B shows the cross section of a panel of the invention.
- Figures 55A-55E show views of the sturdy structure.
- Figures 55A-55C represent the elevation, plan and profile of the resistant structure.
- Figure 55D is a perspective of the resistant structure.
- Figure 55E is the detail C indicated in Figure 55D.
- Figure 55E shows the omega plate for communication of pipes between ceiling and wall. Item 101 in Figure 10 showing the exterior wall and roof nion with eave.
- Figure 57A shows an exploded view of a panel where the components can be seen: concrete cladding 571, mesh 572, sturdy structure 573, polyurethane core 574 and plasterboard 575.
- Some of the materials that can be used in the outer and inner plates are: Polyurea, Cement, MDF, Plaster, OSB, Chipboard of various types, Corrugated or Smooth Metals, Cementitious Plates, Various Resins, Combined Plates (marbled or not) of resins and ground minerals, stone plates (marble and others), solar panel (external plate).
- Figure 57B shows the cross section of a panel of the invention.
- Figure 57C is detail B of Figure 57B.
- Figures 58A-58B show a front view and a perspective of a panel that includes a window.
- Figures 59A-59B show a front view and perspective of a panel that includes a window and a rush.
- connection box 8 corrugated pipe
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Building Environments (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Finishing Walls (AREA)
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2016329634A AU2016329634A1 (en) | 2015-09-30 | 2016-09-29 | Method for producing a wall or roof panel having installations included, walls or roofs pre-fabricated using said method and joints between the wall and roof panels |
US15/765,215 US20180266107A1 (en) | 2015-09-30 | 2016-09-29 | Method for producing a wall or roof module having installations included and walls or roofs prefabricated using said method |
EP16850428.0A EP3358096A4 (en) | 2015-09-30 | 2016-09-29 | METHOD FOR MANUFACTURING WALL OR CEILING PANEL IN WHICH PREFABRICATED FACILITIES, WALLS OR CEILINGS ARE INTEGRATED BY SAID METHOD AND CONNECTION BETWEEN WALL AND CEILING PANELS |
BR112018006538-2A BR112018006538A2 (pt) | 2015-09-30 | 2016-09-29 | método de fabricação de paredes, módulo de teto pré-fabricado e parede pré-fabricada e personalizada |
CA3010888A CA3010888A1 (en) | 2015-09-30 | 2016-09-29 | Method for producing a wall or roof module having installations included and walls or roofs prefabricated using said method |
MX2018003829A MX2018003829A (es) | 2015-09-30 | 2016-09-29 | Pared prefabricada autoportante y liviana, con servicios electricos y sanitarios incluidos, impermeabilizada y de aspecto similar a la construccion tradicional. |
ZA2018/02804A ZA201802804B (en) | 2015-09-30 | 2018-04-26 | Method for producing a wall or roof panel having installations included, walls or roofs pre-fabricated using said method and joints between the wall and roof panels |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
UY36338 | 2015-09-30 | ||
UY0001036338A UY36338A (es) | 2015-09-30 | 2015-09-30 | Pared prefabricada autoportante con servicios electricos y sanitarios incluidos, impermeabilización en poliurea y liviana, pero simil a la construcción tradicional a la vista y al tacto |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2017055669A1 true WO2017055669A1 (es) | 2017-04-06 |
Family
ID=58422698
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/ES2016/070689 WO2017055669A1 (es) | 2015-09-30 | 2016-09-29 | Método de fabricación de panel de pared o techo con instalaciones incluidas, paredes o techos prefabricados por dicho método y uniones entre paneles pared y techo |
Country Status (11)
Country | Link |
---|---|
US (1) | US20180266107A1 (es) |
EP (1) | EP3358096A4 (es) |
AR (1) | AR106078A1 (es) |
AU (1) | AU2016329634A1 (es) |
BR (1) | BR112018006538A2 (es) |
CA (1) | CA3010888A1 (es) |
CL (1) | CL2018000801A1 (es) |
MX (1) | MX2018003829A (es) |
UY (1) | UY36338A (es) |
WO (1) | WO2017055669A1 (es) |
ZA (1) | ZA201802804B (es) |
Cited By (1)
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CN115573559A (zh) * | 2022-10-09 | 2023-01-06 | 中国十九冶集团有限公司 | 一种用于预制凸窗的连梁模板连接件装置 |
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BR202018076317U2 (pt) * | 2018-12-17 | 2020-07-07 | Marcelo Brasil Da Silva | módulos pré-fabricados com painéis metálicos tipo sanduíche com isolante termo acústico em poliuretano e instalações elétricas, hidráulicas e esgoto incorporados |
US11649615B2 (en) * | 2019-07-09 | 2023-05-16 | Lyons House SPC | Lifeline system for compact house |
RU199861U1 (ru) * | 2020-07-03 | 2020-09-23 | Екатерина Петровна Шароварова | Многослойная стеновая панель |
RU204769U1 (ru) * | 2021-01-19 | 2021-06-09 | Общество с ограниченной ответственностью "РУСАПС" | Многослойная несущая панель для образования вертикальных несущих элементов при сборке быстровозводимых зданий |
US20230144278A1 (en) * | 2021-11-11 | 2023-05-11 | RJ Building Materials, LLC | Polyethylene terephthalate (pet) particulate composition for structural construction components |
ES1285250Y (es) * | 2021-11-22 | 2022-04-20 | Baylina Bacardit Mateo Manuel Domingo | Conjunto de elementos perfeccionados para edificacion |
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Also Published As
Publication number | Publication date |
---|---|
MX2018003829A (es) | 2018-09-11 |
AR106078A1 (es) | 2017-12-13 |
EP3358096A4 (en) | 2020-01-29 |
EP3358096A1 (en) | 2018-08-08 |
AU2016329634A1 (en) | 2018-04-26 |
CL2018000801A1 (es) | 2018-06-22 |
UY36338A (es) | 2017-04-28 |
ZA201802804B (en) | 2019-02-27 |
BR112018006538A2 (pt) | 2018-10-16 |
CA3010888A1 (en) | 2017-04-06 |
US20180266107A1 (en) | 2018-09-20 |
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