BRPI0607916A2 - composite panel, insulated concrete formwork, building, and method of building a building - Google Patents

Abstract

COMPOSITE PANEL, ISOLATED CONCRETE FORM, BUILDING, AND METHOD OF BUILDING A BUILDING. A composite building panel including a substantially parallelepiped central body containing an expanded polymer matrix having opposite faces, an upper surface and a lower surface is described; at least one embedded structural member extending longitudinally through the central body between opposing faces having a first end embedded in the expanded polymer matrix, a second end extending outwardly of the lower surface of the central body, and one or more holes expansion in the embedded rafters between the first end of the embedded rafter and the lower surface through which the polymer matrix expands. The concrete layer may optionally cover a portion of the upper and / or lower surface. The building panel may be positioned perpendicular to a structural wall and / or foundation to provide a floor panel. The second end of the frame rafters may be embedded in a second central body to provide an insulated concrete formwork.

Description

"COMPOSITE PANEL, ISOLATED CONCRETE FORM, BUILDING, AND METHOD OF BUILDING A BUILDING"

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to preformed building and construction panels comprising one or more reinforcing structural elements embedded in an expanded thermoplastic matrix as well as insulated concrete formwork with internal locking and strapping elements.

2. Description of the Prior Technology

It is well-known to use building elements made of expanded plastic, for example expanded polystyrene, in plate element shapes or sections of suitable shape and size. These elements provide thermal and acoustic insulation functions and have long been accepted by civil engineering.

It is also known that in order to impart suitable self-supporting properties to such construction elements, one or more reinforcing desection bars must suitably be incorporated into the expanded plastic mass.

U.S. Patent Nos. 5,787,665 and 5,822,940 disclose composite wall panels for building construction that include a regular polymer foam core and at least one lightweight hollow demetal rafter in the body. The edges of the rafters are matched to the surface of the polymer foam so that a plaster wall can be attached to it.

U.S. Patent 6,098,367 discloses a constructive system applied to buildings to form walls by means of modular folding frames allowing the placement of blocks or plates. Sturdy channel, rebar, block or sheet frames are more resilient to strong winds and seismic movements.

US 6,167,624 discloses a method for producing a polymeric expanded material panel including the steps of providing a polymeric expanded material, cutting the polymeric expanded material to a preset cut-off point, subsequently cutting from the preset cut-off point. configure a clamp receiving configuration on the polymer expanded material, and slide a clamp element into the clamp receiving configuration to produce a polymer expanded material panel.

U.S. Patent 6,235,367 discloses a molded construction product having one or more walls and an inner core section, including a composition matrix having a resin system, catalytic agent, and filler composites to form the walls; A foam core system to form the inner core section, a curing agent and a drying agent. A structural reinforcement support system is provided to reinforce the structural integrity of the composition. A locking system is provided for joining one or more of the molded products.

EP 0 459 924 discloses a self-supporting building element made of expanded plastics material, specifically a paving element, which includes a substantially parallelepiped center body in which a reinforcing section bar made of a thin sheet metal shaped as a beam I , is integrated during the demolding step.

U.S. Patent 5,333,429 discloses a composite panel with a load-bearing wooden structural frame formed of a substantially parallelepiped body of expanded synthetic material. The panels have a plurality of longitudinal channels extending the entire height of the panel. A series of evenly spaced and offset channels is open on the adjacent face of the panel and has a T-shaped cross section. These open channels are fitted with T-shaped cross-sectional woodwork, the stem part of which emerges from the open channels and protrudes from the surface of the panel.

WO 2002/035020 discloses a composite construction element including a body made of expanded plastic material and a plate-shaped coating element associated with the body. The plate-cladding element includes a plurality of substantially contiguous and substantially adjacent U-shaped sections provided with respective mechanisms for mechanically grasping the plate-shaped element in the expanded plastics material.

Although the above-described building elements have, on the one hand, low weight, relative ease of installation and low cost, on the other hand, their application in technology and flexibility of use have hitherto been limited by their fire-resistance and / or propensity for mold to grow on finished surfaces attached to them.

This inadequate fire resistance is essentially related to the fact that construction elements made of expanded plastic have insufficient capacity to safely retain external covering layers, such as mortar layers used for external surface finishing, or to keep the expanded polymer body in molten form or flammable liquid, which occurs from the heat generated by a fire.

When exposed to fire, in fact, the plastic expander rapidly contracts into a small, misshapen mass that can shrink and burn, and in some cases, with the resulting separation of the outer covering layers and rapid collapse of the entire structure.

In addition, undesirable separation of the outer covering layers can in some cases be caused by premature "aging" of the plastic surface to which these covers adhere, a separation that may be stimulated by exposure to heat sources, dirt, smoke, vapors. or chemicals from a source close to the building elements.

U.S. Patents 6,298,622 and WO 2004/101905 disclose an approach to overcoming the above problem with the use of a self-supporting expanded plastic construction element for use as paving elements and building walls. The building elements include a central body substantially parallelepiped in shape and having two opposite faces; at least one reinforcement section bar extending transversely in the central body between its faces and embedded in the expanded plastic; a batten for supporting at least one layer of a suitable cover material associated with a fin reinforcing section bar which is arranged flush and substantially parallel with at least one of the faces of the building element.

However, moisture buildup between the batten and the building element can lead to mold growth in the mold, and the ability to easily pass electrical lines without cutting the building elements has limited the convenience of this approach.

Concrete walls in building construction are most often produced primarily by assembling two parallel formwork walls and casting concrete into the space between the formwork. After the concrete hardens, the builder then removes the form, leaving the deconcrete wall cured.

This prior art technique has drawbacks. Deformation of concrete walls is inefficient due to the time required to assemble the formwork, wait until the concrete has cured and remove the formwork. This prior art technique, therefore, is an expensive and labor intensive process.

Thus, techniques have been developed to form modular concrete walls using foam insulating material. Modular formwork walls are mounted parallel to each other and disconnect components hold the two formwork walls in place relative to each other while concrete is cast between them. The formwork walls, however, remain in place after the concrete cures. That is, the walls of the formwork, which are constructed of foam insulating material, are a permanent part of the building after the concrete has cured. The concreted walls using this technique can be stacked on top of each other at many heights to form all walls of the building. In addition to the efficiency achieved by retaining the formwork walls as part of the permanent structure, the formwork wall materials generally provide adequate insulation to the building.

Although the prior art includes many proposed variations to achieve improvements with this technique, there are still drawbacks to each project. The connecting components used in the prior art to retain the walls are constructed from (1) plastic foam, (2) high density plastic, or (3) a metal bridge, which is a nonstructural support, that is, since concrete cure, the disconnect components are without function. Still, these elements provide thermal and acoustic insulation functions and have long been accepted by civil engineering.

Thus, current insulated concrete formwork technology requires the use of small molded foam blocks typically 12 to 24 inches (101.6 mm) (308.4 to 609.6 mm) high with a standard length of four feet (1, 22 meters). The large amount of horizontal and vertical joints that require clamping to properly position blocks during concrete casting restrict their use to shorter wall lengths and lower wall heights. Wall penetrations, such as windows and doors, require highly qualified and engineering training to withstand the pressures exerted on them during concrete placement. Mortar finishing personnel have difficulty hanging plasterboard walls in such systems because of the molding problem located on lining strips. Metal or plastic lining strips in current designs are not continuous in nature and are usually embedded in the foam faces. The characteristics present in the current block forming systems require skilled labor, long laying times, lock specialization and engineering bracing and traditional finishing. This results in a heavier wall not suitable for larger wall construction applications. The highly specialized task force that is required for placing, blocking, bracing and applying finishes in a block system seriously restricts the use of such systems compared with traditional concreting techniques.

One approach to solving the problem of true straight walls in larger schemes has been to design larger blocks. Current existing manufacturing technology has limited this increase to 24 inches (101.6 mm) (609.6 mm) in height and eight feet (2.44 meters) in length. Other systems create expanded plastic panels and hot-line cutting posts mechanically bonded together in a secondary operation using metal or plastic connectors. These panels are typically 48 inches (1,219.2 millimeters) wide and 8 feet (2.44 meters) high and do not have continuous lining strips.

However, none of the above-described approaches adequately address the formwork problems at higher wall heights due to the pressure exerted by the cast concrete, rapid ease of construction with an unskilled task force, and ease of wall finishing with easily determined attachment points.

Thus, there is a need in the technology of composite preformed building panels and insulated concrete formwork with internal locking and fixing elements that overcome the above problems.

SUMMARY OF THE INVENTION

The present invention provides a composite construction panel comprising:

a substantially parallelepiped central body containing an expanded polymer matrix having opposite faces, an upper surface and an opposite lower surface; at least one built-in structural rafter extending

longitudinally through the central body between the opposing faces, having a first end embedded in the expanded polymer matrix, a second end extending outwardly from the lower surface of the central body, and one or more expansion holes located in the embedded rafters between the first end of the embedded rafters. and the lower center body surface, wherein the central body contains a polymer matrix that expands through the expansion holes; a concrete layer covering at least a portion of the upper surface and / or lower surface.

The present invention also provides a composite deboring panel which includes:

a substantially parallelepiped central body containing an expanded polymer matrix having opposite faces, an upper surface and an opposite lower surface; one or more recessed floor support bars

extend longitudinally through the central body between opposite faces which have a first end embedded in the expanded polymer matrix having a first transverse element extending from the first end generally in contact with or extending above the upper surface, a second end extending outwardly. the lower surface of the central body having a second transverse element extending from the second end, and one or more expansion holes located in the rafters embedded between the first end of the embedded rafters and the lower surface of the central body;

wherein the central body contains a polymer matrix that expands through the expansion holes; wherein the space defined by the lower surface of the central body and the second ends of the embedded bars is adapted to accommodate utility lines; and

where the composite floor panel is positioned generally perpendicular to a wall and / or structural foundation.

The present invention further provides an isolated deconcrete formwork comprising:

a substantially substantially parallelepiped first body including an expanded polymer matrix having opposing faces, a first surface, and an opposite second surface;

a second body, substantially parallelepiped in shape, including an expanded polymer matrix having opposing faces, a first surface, a second opposite surface; and

one or more inlaid rafters extending longitudinally through the first body and the second body between the first surfaces of each body, having a first end embedded in the expanded polymer matrix of the first body, and a second end embedded in the expanded polymer matrix of the second body, a or more expansion holes located in the portion of the rafters embedded in the first body and the second body;

wherein the first body and the second body contain a polymer matrix that expands through the expansion holes; and the defined space between the first surfaces of the first body and the second body is capable of accepting concrete cast into it.

The present invention further provides an insulated concrete formwork system comprising a plurality of the above-described insulated concrete formwork where at least one of an outer ferrule or an inner ferrule of each insulated concrete formwork joins with another insulated concrete formwork.

The present invention further relates to buildings containing one or more of the insulated building panels, floor panels, insulated concrete formwork and above-described insulated concrete formwork systems.

The present invention further relates to a method of constructing a building comprising:

mount the aforementioned composite building panels on a generally flat surface, and

lift a first end of the composite building panel while a second end remains stationary, resulting in the orientation of the building panel to form a building wall.

The present invention also relates to a building constructed according to the above method.

DESCRIPTION OF DRAWINGS

Figure 1 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 2 shows a side elevation view of a preformed building panel according to the invention;

Figure 3 shows a perspective view of a construction method according to the invention;

Figure 4 shows a partial perspective view of a level track according to the invention Figure 5 shows a rear elevation view of a wall system according to the invention;

Figure 6 shows a front perspective view of a wall system according to the invention;

Figure 7 shows a rear side perspective view of a wall system according to the invention;

Figure 8 shows an exploded perspective view of a portion of the wall system of Figure 7;

Figure 9 shows a perspective view of a wall system according to the invention;

Figure 10 shows a partial top perspective view of a molding attached to a preformed building panel according to the invention;

Fig. 11 shows a cross-sectional view of the molding in Fig. 10;

Figure 12 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 13 shows a perspective view of a depaving system according to the invention; and

Figure 14 shows a perspective view of a depaving system according to the invention;

Figure 15 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 16 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 17 shows a cross-sectional view of a preformed concrete composite building panel system according to the invention;

Figure 18 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 19 shows a perspective view of a demetal rafter used in the invention;

Figure 20 shows a cross-sectional view of a preformed concrete composite building panel system according to the invention;

Figure 21 shows a cross-sectional view of a preformed concrete composite building panel system according to the invention;

Figure 22 shows a cross-sectional view of a preformed building panel according to the invention;

Figure 23 shows a perspective view of a demetal rafter used in the invention;

Figure 24 shows a cross-sectional view of a preformed concrete composite building panel system according to the invention;

Figure 25 shows a cross-sectional view of a preformed concrete composite building panel system according to the invention;

Figures 26, 27 and 28 show a cross-sectional view of metal rafters that may be used in preformed building panels according to the invention;

Fig. 29 shows a partial elevation view of a preformed building panel according to the invention;

Figure 30 shows a top plan view of an isolated preformed deconcrete formwork according to the invention;

Figure 31 shows a top plan view of an isolated preformed deconcrete formwork according to the invention;

Figure 32 shows a cross-sectional view of a preformed insulated concrete formwork according to the invention;

Fig. 33 shows a partial perspective view of an inboard crimp used in the invention;

Figure 34 shows a perspective view of an isolated preformed deconcrete formwork according to the invention;

Fig. 35 shows a perspective view of the concrete and the embedded rafter portion of an insulated concrete formwork according to the invention;

Figure 36 shows a perspective view of the concrete and the portion of the inlaid rafter of an insulated concrete formwork according to the invention;

Figure 37 shows a partial perspective view of a metal crimp used in the invention;

Fig. 38 shows a plan view of an isolated deconcrete formwork system according to the invention;

Fig. 39 shows an isolated deconcrete formwork unit according to the invention; and

Fig. 40 illustrates the manufacturer / customer method of designing custom composite building panels according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

For the purpose of the following description, the terms "upper", "lower", "internal", "external", "right", "left", "vertical", "horizontal", "top", "base" and its derivatives should be related to the invention in the manner oriented in the drawings figures. However, it should be understood that the invention may assume variations and alternate step sequences except where expressly specified otherwise. It should also be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification is an exemplary embodiment of the present invention. Accordingly, specific dimensions and other physical characteristics related to the embodiment disclosed herein should not be construed as limiting the invention. In describing the embodiments of the present invention, reference will be made to the drawings, in equal numbers referring to equal features of the invention.

Unless otherwise indicated, all numbers or expressions referring to quantities, distances or measurements, etc., used in the specification and claims are to be understood modified in all cases by the term "about". Thus, unless otherwise indicated, the numerical parameters set forth in the following specification and the appended claims are approximations which may vary depending upon the properties the present invention wishes to obtain. At the very least, and not as an attempt to limit the application of the equivalent doctrine to the scope of claims, each numerical parameter should be at least interpreted in light of the number of significant digits reported and ordinary rounding techniques applied.

No matter that the numerical ranges and parameters that define the broad scope of the invention are approximations, the numerical values given in the specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors that necessarily result from the standard deviation found in their respective measurement methods.

Also, it should be understood that any acquired numeric range must include all subtotaled sub-ranges therein. For example, a range of "1 to 10" should include all intermediate sub ranges and including the minimum quoted value of 1 and the maximum quoted value of 10; that is, having a minimum value of 1 or greater and a maximum value of 10 or less. Because the revealed numeric ranges are continuous, they include each value between the minimum and maximum values. Unless expressly stated otherwise, the various number ranges specified in this application are approximations.

As used herein, the term "expandable polymer matrix" refers to a particulate or beaded polymeric material, i.e. impregnated with a blowing agent such that when the particulates and / or beads are placed into As a mold and heat is applied to it, evaporation of the blowing agent (as described below) affects the formation of the cellular structure and / or an expanding cellular structure in the particles and / or beads, and the external surfaces of the particles and / or beads. fuse to form a continuous mass of polymeric material that fits the shape of the mold.

As used herein, the term "polymer" shall include, without limitation, homopolymers, copolymers and graft copolymers.

As used herein, the terms "(meta) acrylic" and "(meta) acrylate" shall include both commethacrylic acid derivative such as the corresponding alkyl esters generally referred to as acrylates and (meta) acrylates, as the term "( meta) acrylate "should be used.

The present invention provides preformed building panels including one or more longitudinally disposed structural members or reinforcement bars which are partially exposed with the rest of the partially encapsulated reinforcement structural element (s) in a matrix expanded polymer, which acts as a thermal breaker. Structural reinforcement elements can be flanged lengthwise on either side to provide attachment points for external objects to the panel. Perforations in the reinforcing structural elements that are encapsulated in the expanded polymer matrix allow melting perpendicularly. Perforations in the exposed portions of the reinforcing structural member provide attachment points for lateral attachment and utility installation. A male and female connection point design provides panel support, exhaust holes, and attachment points for external objects. Recessed areas at opposite ends of the panel provide an element-to-element connection area, with "C" channels being arranged along the end. and the base of the structural element. Longitudinal holes in the expanded polymer matrix vary in diameter and location and provide areas for utility placement, lightening the structure and channels for venting gases. Panel manufacturing takes place by the use of a semicontinuous or continuous molding process that allows various panel lengths.

The inlaid frame rafters or floor bars used in the invention may be made of any suitable material. Suitable materials are those that increase the strength, stability and structural integrity of the preformed building panels. Such materials provide built-in frame rafters that meet the requirements of applicable test methods known in the art, such as non-limiting examples, ASTM A 36 / A 36M-05, ASTM A 101 l / A 1011M-05a, ASTM A1008 / A 1008M-05b and ASTM A 1003 / A 1003M-05 for various types of steel.

Suitable materials include, but are not limited to metals, construction grade plastics, composite materials, ceramics, combinations thereof and the like. Suitable metals include, but are not limited to, aluminum, steel, stainless steel, tungsten, molybdenum, iron and alloys and combinations of such metals. In a particular embodiment of the invention, bars, rafters, bars and / or metal elements are made of a thin metal.

Suitable construction grade plastics include, but are not limited to, reinforced thermoplastics, thermosetting resins, and reinforced thermosetting resins. Thermoplastics include polymers and polymer foams made of materials that can be repeatedly softened by heating and hardened again upon cooling. Suitable polymerethermoplastics include, but are not limited to, styrene ecopolymers and polymers, C2 to C20 olefin homopolymers and copolymers, C4 to C20 dienes, polyesters, polyamides, homopolymers and copolymers of C2 to C2 (meth) acrylate, polyetherimides, polycarbonates, polycarbonates, polyetherethers (vinyl chlorides), polyurethanes and combinations thereof.

Suitable thermocure resins are resins that, when heated to their point of cure, undergo a chemical crosslinking reaction, causing them to solidify and maintain their rigidities even at elevated temperatures. Suitable thermosetting resins include, but are not limited to, alkyd resins, epoxy resins, diallyl phthalate resins, melamine resins, phenolic resins, depolyester resins, urethane and urea resins, which may be cross-linked by reaction, such as non-limiting examples, with diols, triols, polyols and / or formaldehyde.

Reinforcement materials and / or fillers that may be incorporated into thermoplastics and / or thermocouple resins include, but are not limited to, carbon fibers, aramid fibers, glass fibers, metal fibers, structured fabric or fiber structures mentioned, fiberglass. , carbon black, graphite, clays, calcium carbonate, titanium dioxide, structured fabric or structures of the aforesaid fibers and combinations thereof.

A non-limiting example of construction grade plastic is glass fiber reinforced resin thermosetting polyester or vinyl ester systems that meet the requirements of the test methods known in the art, non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTM D638 .

Thermoplastics and thermosetting resins may optionally include other additives, such as a non-limiting example, ultraviolet stabilizers (ITT), thermal stabilizers, flame retardants, structural reinforcements, biocides and combinations thereof.

Recessed frame rafters or support bars of recessed floors (recess bars) may have a thickness of at least 0.4 mm, in some cases at least 0.5 mm, in other cases at least 0.75 mm, in some instances. at least 1 mm, in other occurrences at least 1.25 mm and in some circumstances at least 1.5 mm and may have a thickness of up to 10 mm, in some cases up to 8 mm, in other cases up to 6 mm, in some occurrences up to 4 mm and in other cases up to 2 mm. The thickness of the inlaid frame rafters or the unbuttoning bars of the inlaid floors will depend on the intended use of the preformed construction panel.

In one embodiment of the invention, the inlaid bars, rafters, barothesis / or reinforcement elements have holes or openings along their length to facilitate melting of the expanded plastics material and reduce any thermal bonding effect on the bars, rafters, bars and / or reinforcement elements. .

The expanded polymer matrix constitutes the expanded polymer body described hereinafter. The typically molded expanded polymer matrix of expandable thermoplastic particles. Such expandable thermoplastic particles are made of any suitable thermoplastic homopolymer or copolymer. Particularly suitable for use are homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert-butylstyrene and the like, as well as copolymers prepared by copolymerizing at least one aromatic monomer with one or more of the above-described monomers nonlimiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1, 3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, where vinyl monomer is present at least 50% by weight of the copolymer. In one embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers may be used, such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates, polyphenylene oxides and mixtures thereof.

In a particular embodiment of the invention, expandable thermoplastic particles are expandable polystyrene (EPS) particles. These particles may be in the form of beads, granules, or other particles suitable for expansion and molding operations. Polymerized particles in an aqueous suspension process are essentially spherical and are used for molding the expanded polymer body described hereinafter. These particles can be selected so that their sizes range from about 0.008 inch (0.2 mm) to about 0.1 inch (2.5 mm).

At . Expandable thermoplastic particles may be suitable. As a non-limiting example, impregnation may be achieved by adding the blowing agent to the aqueous suspension during polymer polymerization or, alternatively, by resuspending the polymer particles in an aqueous medium and then incorporating the blowing agent in the manner prescribed herein. US Patent 2,983,692. Any gaseous material or material that produces gases upon heating may be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and halogenated hydrocarbons, for example CFCs and HCFCS, which boil at a temperature below the softening point of the chosen polymer. Mixtures of such aliphatic hydrocarbon blowing agents may also be used.

Alternatively, water may be mixed with such aliphatic hydrocarbon blowing agents, or water may be used as the sole blowing agent as set forth in U.S. Patent Nos. 6,127,439,6,160,027 and 6,242,540. In these patents water retention agents are used. The weight percent of water for use as the blowing agent could range from 1 to 200. The texts of U.S. Patent Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein by reference.

Impregnated thermoplastic particles are generally pre-expanded to a density of at least 0.5 lb / ft3 (0.008 g / cm3), in some cases at least 1 lb / ft3 (0.016 g / cm3), in other cases at least1, 25 lb / ft3 (0.02 g / cm3), in some situations at least 1.5 lb / ft3 (0.024g / cm3), in other situations at least 2 lb / ft3 (3.2 g / cm3) (0.032 g / cm3), and in some instances at least about 3 lb / ft3 (0.048 g / cm3). Also, the density of the pre-expanded impregnated particles can be up to 35 lb / ft3 (0.56 g / cm3), in some cases up to 30 lb / ft3 (0.48 g / cm3), and in other cases up to 25 lb / ft3. ft3 (0.4 g / cm3). The density of the pre-expanded impregnated particles may be any value, or may vary from any of the above values. The pre-expansion step is conventionally performed by heating the beads impregnated by any conventional heating means such as steam, hot air, hot water or radiant heat. A generally accepted method of pre-expanding impregnated thermoplastic particles is set forth in U.S. Patent 3,023,175.

The impregnated thermoplastic particles may be expanded cellular polymer particles as set forth in U.S. Patent Application. 10 / 021,716, the provisions of which are incorporated herein by reference. The expanded cell particles may be polystyrene which are pre-expanded and contain a volatile blowing agent at a level of less than 6.0 percent by weight, in some cases ranging from about 2.0 pp to about 5.0 pp and in other cases ranging from about 2.5 pp to about 3.5 pp based on the weight of the polymer.

An interpolymer of a polyolefin and in situ polymerized aromatic vinyl monomers which may be included in the expandable thermoplastic resin according to the invention is disclosed in U.S. Patents. Nos. 4,303,756 and 4,303,757 and U.S. Application Publication 2004/0152795, the relevant parts of which are incorporated herein by reference. A nonlimiting example of interpolymers which may be used in the present invention include those available under the trade name ARCED, available from NOVA Chemicals Inc., Pittsburgh, PA and PIOCELAN, available from Sekisui Plastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix may include customary additive ingredients such as pigments, dyes, colorants, plasticizers, mold release agents, stabilizers, ultraviolet light absorbers, mold prevention agents, antioxidants and the like. Typical pigments include, without limitation, inorganic pigments such as carbon black, graphite, expandable graphite, zinc oxide, detitanium dioxide, and iron oxide, as well as organic pigments such as quinacridone violet reds and copper phthalocyanine blues and greens .

In a particular embodiment of the invention, the smoke black pigment, a non-limiting example of such a material being EPS SILVER®, available from NOVA Chemicals Inc. In another particular embodiment of the invention the pigment is graphite, a non-limiting example of such a material being NEOPOR®, available from BASFAktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.

When materials such as carbon black and / or graphite are included in the polymer particles, better insulation properties, exemplified by higher R values for carbon black or graphite containing materials (determined using A.STM - C578), are provided. Overall, the R-value of carbon black and / or graphite-containing expanded polymer particles or materials made of such polymer particles is at least 5% higher than those observed for particles or resulting articles that do not contain carbon black and / or graphite. The pre-expanded or pre-puff particles are heated in a closed mold in the following semicontinuous or continuous molding process to form the preformed building panels according to the invention.

The expanded polymer body used in the invention includes holes, ducts, or notches that are molded and extend along the length of the expanded polymer body. In one embodiment of the invention, holes, ducts, or notches are used to provide access paths for utilities such as wiring, plumbing, and exhaustion through walls, ceilings, floors, and roofs constructed in accordance with this invention.

In another embodiment of the invention, the wall units, floor units and expanded polymer panels or center body have a "tongue" male edge and a "notch" female edge that facilitate the "male and female" joint of two wall units, unpaving units and matched expanded polymer panels. The male and female joint may be nonlinear and may provide a vent hole and / or wider opening to accommodate hydraulic piping. Typically, the male and female joint provides a flat surface to the joint to facilitate the application of phytoliquid to seal the joint or joint.

One embodiment of the present invention provides wall units and wall systems. As shown in Figure 1, the wall unit includes expanded polymer body 12 (center body), left-facing recessed demetal rafters 14, and right-facing recessed metal rafters 16 (recessed reinforcement bars). The expanded polymer body 12 includes openings 18 that traverse all or part of the expanded polymer body length 12. The embossed metal rafters 14 and 16 have recessed ends 20 and 22 respectively that do not touch the outer surface 24 of the expanded polymer body 12.The rafters Embedded metal plates 14 and 16 also have exposed ends 26 and 28 respectively extending from the inner surface 30 of the expanded polymer body 12.

The expanded polymer body 12 may have a thickness 5, measured as the distance from the inner surface 30 to the outer surface 24 of at least 2, in some cases at least 2.5, and in other cases at least 3 cm and may be up to 10, in some cases up to 8, and in other cases up to 6cm from the inner surface 30 of the expanded polymer body 12. Embedded ends 26 and 28 may extend either distance, or may vary between any of the above distances from the inner surface 30.

Exposed ends 26 and 28 extend at least 1, in some cases at least 2, and in other cases at least 3 cm outside the inner surface 30 of the expanded polymer body 12. Also, exposed ends 26 and 28 may extend to 60 , in some cases up to 40, and in other cases up to 20 cm off the inner surface 30 of the expanded polymer body 12. In many cases, the exposed ends 26 and 28 extend from the polymer body 12 a sufficient distance to allow utilities to pass along of the inner surface 30 in the water-written manner. Exposed ends 26 and 28 may extend either of the distances, or may vary between any of the above distances of the inner surface 30.

Embedded ends 20 and 22 extend at least 1, in some cases at least 2, and in other cases at least 3 cm within the expanded polymer body 12 off the inner surface 30.

Also, the embedded ends 20 and 22 may extend up to 10, in some cases up to 8, and in other cases up to 6 cm off the inner surface 30 into the expanded polymer body 12. In many cases, the embedded ends 20 and 22 extend a distance to the interior of the expanded polymer body 12 such that the embedded ends 20 and 22 do not contact the outer surface 24. Defined depth between outer surface 24 and embedded ends 20 and 22 defines a thermal breaker. Embedded ends 26 and 28 may extend either distance, or may vary between any of the aforementioned distances from the inner surface 30 to the interior of the polymer body 12.

In another embodiment of the invention, the butt ends 20 and 22 may extend from 1/10 to 9/10, in some cases 1/3 to 2/3 and in other cases 1/4 to 3/4 of the body thickness. expanded polymer12 within the expanded polymer body 12.

In one embodiment of the invention, inlaid metal rafters 14 and 16 have a cross-sectional shape that includes inlay lengths 34 and 36, inlaid ends 20 and 22 and exposed ends 26 and 28. The orientation of inlaid metal rafters 14 and 16 is referred to by direction of open ends 38 and 40. In one embodiment of the invention, open ends 38 and 40 are oriented away from each other. In this embodiment, the wall unit 10 is stiffer and easier to handle without folding.

The spacing between each of the inlaid metal rafters 14 and 16 is typically adapted to be consistent with local building codes or methods, but may be modified to suit special needs. As such, the spacing between metal rafters may be at least 10, in some instances at least 25 and in some cases at least 30 cm and may be up to 110, in some cases up to 100, in other cases up to 75, and in some instances up to 60 cm, measured from a point at the opposite end 26 to a point at the opposite end28. The spacing between inlaid metal rafters 14 and 16 may be at any distance, or may vary between any of the aforementioned distances.

The openings 18 may have various cross-sectional shapes, non-limiting examples being round, oval, elliptical, square, rectangular, triangular, hexagonal or octagonal. The cross-sectional size of openings 18 may be uniform, or they may vary independently of each other with respect to size and location with respect to the inner surface 30 and the outer surface 24. The gap spacing aperture 18 may be at least 5 and in some cases at least 10 cm can be up to 110, in some cases up to 100, in other cases up to 75, and some occurrences up to 60 cm, measured from a midpoint of an aperture 18 to an adjacent aperture 18. The spacing between openings 18 can be regardless of any distance, or may vary between any of the above distances.

The cross-sectional areas of the openings 18 may also vary independently of each other, or they may be uniform. The cross-sectional areas of the openings 18 are limited by the dimensions of the expanded polymer body 12, provided that the openings 18 fit the dimensions of the expanded polymer body 12. The cross-sectional areas of the openings 18 may be independently at least 1, in some cases at least 5. , and in other cases at least 9 cm2e can be up to 130 cm, in some cases up to 100 cm, in other cases up to 75 cm2. The cross-sectional areas of the openings 18 may independently have any value, or may vary from any of the above values.

As shown in Figure 1, the expanded polymer body 12 may extend for a distance with alternating metal embeders 14 and 16 placed therein. The wall unit length 10 can be any length that allows safe handling and minimal damage to the wall unit 10. The wall unit length 10, defined as the distance from the receiving end 27 to the male terminal end 21, can typically be at least at least 1, in some cases at least 1.5, and in other cases at least 2m and may be up to 25, in some cases up to 20, in other cases up to 15, in some instances up to 10, and in other instances up to 5 m. Wall unit length 10 may be any value, or may vary from any of the above values. In some embodiments of the invention, each wall unit end 10 terminates with a built-in metal rafter.

The height of wall unit 10 can be any height that allows safe handling and minimal damage to wall unit 10. The height of wall unit 10 is determined by the length of the built-in demetal rafters 14 and 16. The height of wall unit 10 can be be at least 1 m and in some cases at least 1.5 m and may be up to 3 m and in some cases up to 2.5 m. In some instances, in order to increase the stability of the wall unit 10, reinforcing sleepers (not shown) may be attached to the inlaid metal rafters 14 and 16. The height of the wall unit 10 may be any value, or may vary between any of the above values.

As shown in Figure 1, expanded polymer body 12 has a finite length 72 and has a male end end 21 which includes front edge 23 and exit edge 25 and a recess end 27 including recessed section 29 and extended section 31 which is adapted to receive front edge 23, and exit edge 25. Typically, lengths of wall units 10 are interconnected by inserting a front edge 23 of a first wall unit 10 into a lowered section 29 of a second wall unit 10. In this manner, A larger wall section containing any number of wall units can be mounted and / or arranged.

Wall unit 10 is typically part of a general wall system 21 shown in figures 3-11. A lower end of the inlaid metal rails 14 and 16 is seated and attached to the lower runway 44e and the upper slide runway 42. This configuration leads to the lower channel formation 52 and upper channel 54. Channels 52 and 54 may be filled with polymer material correspondingly expanded or, alternatively, with a molding molded to fit into channels 52 or 54.

As a non-limiting example, molding 5B may be inserted into upper channel 54 and attached to upper slide track 42 by inserting fasteners 60 into holes 62 in upper slide track 62 shown in figures 10 and 11. Molding 58 provides a thermal breaker for opposite metal track.

Channels 52 and 54 provide an advantageous feature of the present invention since the channels at the ends of the panels expose the embedded metal rafters 14 and 16 on both sides. This feature overcomes a basic structural problem in the prior art by providing a positive mechanical connection to both sides of the metal rafters when upper runway 42 and lower runway 44 are installed.

Referring to Figures 3, 5 and 7-9, the metal embossed rafters 14 and 16 may have utility holes 46 spaced along their length. Utility holes 46 are used to accommodate utilities such as wiring for electricity, telephone, cable television, speakers, and other electronic devices, gas lines, and hydraulic lines (shown particularly in Figure 9). Utility holes 46 may have various transverse sectional shapes, non-limiting examples being round, oval, elliptical, square, rectangular, triangular, hexagonal or octagonal. The cross-sectional areas of utility holes 46 may also vary independently of each other, or they may be uniform. The cross-sectional area of utility holes 46 is limited by the dimensions of inlaid metal rails 14 and 16, as utility holes 46 will square in size and will not significantly impair structural integrity and strength. The cross-sectional area of the deutility holes 46 may be independently at least 1, in some cases at least 2, and in other cases at least 5 cm 2 and may be up to 30, in some cases up to 25, in other cases up to 20 cm 2. The cross-sectional areas of the openings 18 may independently have any value, or may vary any of the above values.

In one embodiment of the invention, utility holes 46 may have a flanged surface and, in many cases, a laminated flanged surface to provide greater resistance to embedded metal rafters. Flanged holes allow the use of smaller gauge materials to achieve the same structural properties.

The wall system 21 is shown in figures 5-8, where three wall units are connected. Where the ends of two wall units meet to form a corner, an outer corner attachment 47 secures the ends of the two wall units to each other. Also, additional metal rafters 49 may be included to increase the strength of formed corners. Thus, the wall system includes lower sliding 44 and upper sliding runners 42 and embedded interconnected demetal end rafters 51 interlocked 51 secured to corner attachment units extending along the height of each wall unit.

Window and door openings are provided by constructing the ends of the opening with two or more inlaid metal rafters placed adjacent one another (shown as 53). The upper element55 and the lower element 57 are connected to the embedded metal rafters to form a framed structure. The openings are adapted to easily accept prefabricated windows and doors.

The strength and integrity of the wall system 21 may be improved by including extension bars 61 that are arranged to pass through openings, such as utility holes 46, in metal-embossed rafters 14 and 16. Extension bars 61 are attached to metal-embossed rafters 14 and 16 and are arranged, as shown, in a relationship generally perpendicular to the metal rafters 14 and 16, extension bar 61 may be arranged to form any suitable angle with embedded metal rafters 14 and 16 that increases the strength and integrity of the wall system 21. Extension bars and metal rafters which may be incorporated into the invention include those available under the tradename TRADEREADY® SPAZZER® available from DietrichIndustries, Inc., Pittsburgh, PA as well as those disclosed in US Patent 5,784,850 and 6,021,618, the portions of which Relevant information is incorporated herein by reference.

The various metal structural parts in the wall system 21 may be secured or attached to each other by welding 71 and / or screws 73.

Particular advantages of the present wall units and wall systems include the ability to easily pass utilities before attaching a trim surface to the exposed ends of the inlaid metal rails. Exposed metal rafters facilitate changes and additions of structural framing in the field and leave exposed structural parts of the assembly for local public inspectors to inspect the frame.

Referring to Figure 9, in one embodiment of the invention, the wall unit 10 includes expanded polymer body 12 (center body), right-facing recessed metal rafters 16 (reinforcing recessed bars) which include flanges 11 and have holes 46 located on an exposed portion of the embedded rafters 16, expansion holes 13 in an embedded portion of the embedded rafters 16 and an embedded end 22, which do not touch the outer surface 24 of the expanded polymer body 12. The embedded metal rafters 16 also have opposite end 28 respectively extending from the inner surface 30 of the expanded polymer body 12.

Expansion holes 13 are used in which, as expanded polymer body 12 is molded, the polymer matrix expands through expansion holes 13 and the expanding polymer melts. This allows a polymer matrix to surround and hold the caudous embossers 16 by melting into the expanding polymer. In one embodiment of the invention, expansion holes 13 may have a flanged surface and, in many cases, a laminated flange surface to provide greater resistance to embedded metal rafters.

A utility space defined by the inner surface 30 of the expanded polymer body 12 and flanges 11 adapted to accommodate utilities is provided. Typically, flanges 11 have a finishing surface (as described herein) attached thereto, one side of which further defines the utility space.

In one embodiment of the invention, the utility space is adapted and sized to receive standard and / or prefabricated components such as windows, doors and medicine cabinets, as well as individualized cabinets and shelves.

In one embodiment of the invention, utility holes 46 are adapted to allow utilities (as shown, power line 15) to pass in a transverse direction relative to the embedded rafters 16.

Utilities may be one or more selected from hydraulic lines (both potable and, as a non-limiting example, radiant heating hot water lines), waste lines, notches, telephone lines, cable television lines, computer lines, fiber optic cables. , satellite dish communication lines, antenna lines, power lines, ductwork and gas lines. In a particular embodiment of the invention, the wall unit 10 is attached to the lower lane 44. In this embodiment, the lower lane 44 is adapted to contain a volume at least equivalent to the expanded polymer matrix volume in the expanded polymer body 12, in the formaliquid or melt. In some instances, this volume may be defined by the base 101 and sides 103 of the lower runway 44, and the portions of the rafters 16 in space defined by the lower runway 44.

Non-limiting examples of suitable finish surfaces include wood, rigid plastic, wood panels, decay panels, cement panel, plasterboard, slate, particulate boards, rigid plastic panels, a metal batten, their combinations, or any other suitable material. with decoration and / or structural functions.

Additionally, the air gap between the expanded polymer body inner surface and the finishing surface allows for better air circulation, which can minimize or prevent mold formation. In addition, because metal rafters do not come in direct contact with the outer surface, thermal bonding through the highly conductive embedded rafters is avoided and insulation properties are improved.

The present invention also provides paving units and paving systems that include composite paving panels. Flooring panels generally include a substantially parallelepiped central body containing an expanded polymer matrix having opposite faces, an upper surface and an opposite lower surface; and two or more downwardly supporting members of the flats extending longitudinally through the central body between opposing faces having a first end embedded in the expanded polymer matrix having a first transverse element extending from the first end generally making contact or extending above the upper surface, a second end extending outwardly from the lower surface of the central body having a second transverse element extending from the second end, and one or more expanding holes located in the floor support beams recessed between the first end of the base support beams. recessed floors and the lower central body surface. The central body contains a superscript polymer matrix that expands through the expansion holes. Recessed floor support bars include one or more disability holes located in the recessed bars between the bottom center body surface and the second end of the recessed bars and the space defined by the bottom surface of the center body and the second ends of the recessed floor support bars are adapted. to accommodate utilities. The composite floor panel is positioned perpendicular to a structural wall and / or foundation.

As shown in FIG. 12, the paving unit 90 includes expandable polymer panel 92 (center body) and recessed metal bars 94 and 96 (recessed reinforcing bars). The expandable polymer panel 92 includes openings 98 that traverse all or part of the length of the expanded polymer panel 92. The embossed metal bars 94 and 96 have recessed ends 104 and 106 respectively that contact the upper surface 102 of the expanded polymer panel 92. The bars Embedded metal plates 94 and 96 also have exposed ends 108 and 110 respectively extending from the lower surface 100 of the expanded polymer panel 92.

Embedded metal bars 94 and 96 include first transverse members 124 and 126 respectively extending from recessed ends 104 and 106 respectively which generally contact the upper surface 102 and exposed ends 108 and 110 include second transverse elements 128 and 129 respectively. extending from the exposed ends 108 and 110, respectively. The space defined by the bottom surface 100 of the expanded polymer panel 92 and the exposed ends 108 and 110 and second transverse members 128 and 129 of inlaid metal bars 94 and 96 may be oriented to accept conduit networks placed between inlaid metal bars 94 and 96 adjacent to the surface. lower 100.

The expanded polymer panel 92 may have a thickness, measured as the distance from the upper surface 102 to the lower surface 100, of dimensions similar to those relative to the expanded polymer body 12.

The exposed ends 108 and 110 extend at least 1, in some cases at least 2, and in other cases at least 3 cm outside the bottom surface 100 of the expanded polymer panel 92. Also, the exposed ends 108 and 110 may extend up to 60, in some cases up to 40, and in other cases up to 20 cm off the bottom surface 100 of the expanded polymer panel 92. The exposed ends 108 and 110 may extend either distance, or may vary between any of the above distances from the bottom surface. 100

In one embodiment of the invention, recessed metal bars94 and 96 have a cross-sectional shape that includes recess lengths 114 and 116, recessed ends 104 and 106, and exposed ends 108 and 110. The orientation of recessed metal bars 94 and 96 is referenced by open ends direction 118 e120. In one embodiment of the invention, open ends 118 and 120 are oriented towards each other. In this mode, the paving unit 90 is adapted to accept conduit networks. As a non-limiting example, an HVAC duct may be installed along the length of recessed demetal bars 94 and 96.

As used herein, the term "conduit networks" refers to any pipe, pipe, channel, or other closures through which arpode may flow from a source into a receiving space; non-limiting examples being air flowing from heating and / or air conditioning equipment into an environment, build-up air flowing from an environment into heating and / or air conditioning equipment, cooling air flowing into a confined space and / or waste air that flows from a confined space to a location outside the confined space. In some embodiments, conduit networks include generally rectangular metal tubes which are located below the floor and generally extend adjacent to it.

The spacing between each of the inlaid metal bars94 and 96 may be as described with respect to the metal-embossed rafters 14 and 16 in the wall unit 10.

The openings 98 may have various cross-sectional shapes and similar spacing and cross-sectional area as described with respect to the openings 18 in the expanded polymer body 12.

As shown in Fig. 12, the expanded polymer panel 92 may extend for a distance with alternating metal embeded bars 94 and 96 placed therein. Paving unit length 90 can be any length that allows safe handling and minimal damage to paving unit 90. Paving unit length 90 can be described with respect to wall unit length 10. In some embodiments, one end of paving unit 90 can end with a built-in metal bar.

As shown in Figure 12, the expanded polymer panel 92 has a finite length and has a flat end end 91 that includes front edge 93 and exit edge 95 and a receiving end 97 that includes lowered section 99 and extended section 101, which is adapted to receive front edge 93, and trailing edge 95. Typically, lengths of paving units 90 are interconnected by inserting a front edge 93 by a first paving unit 90 into a lowered section 99 by a second paving unit 90. Thus, a larger section The pavement containing any number of paving units can be assembled and / or arranged.

The width of the paver unit 90 can be any width that permits safe handling and minimal damage to the paver unit 90. The width of the paver unit 90 is determined by the length of the recessed metal bars 94 and 96. The width of the paver unit 90 can be at least 1 and in some cases at least 1.5 m and may be up to 3 m and in some cases up to 2.5 m. In some instances, in order to increase the stability of the paver unit 90, reinforcing sleepers (not shown) may be attached to the built-in demetal bars 94 and 96. The width of the paver unit 90 may be any value between any of the above values.

Paving unit 90 is typically part of the system that includes a plurality of panels described herein, wherein the male ends include a tongue edge and the female ends 15 include a tongue edge and the female ends include a notch arranged such that a tongue and / or Each notch is in sufficient contact with a tongue and / or notch corresponding to another panel to form a plane. The established plane extends laterally from a foundation and / or a structural wall.

In the present paving system, duct nets may be attached to the reinforcing metal bars of at least one composite paving panel. In addition, a paving material may be attached or in contact with one or more of the first transverse members of the composite paving panels. . Any suitable paving material may be used in the invention. Suitable paving materials are materials that can be attached to the transverse elements and cover at least a portion of the expanded polymer panel. Suitable flooring materials include, but are not limited to, plywood, wood planks, male and female paving sections, sheet metal, structural plastic sheets, stone, ceramics, cement, concrete and combinations thereof.

In general, the paving system forms a plane extending laterally from a foundation and / or a structural wall.

Figures 13 and 14 show paving systems 140 and 141, respectively. The paving system 140 is established by contacting the leading edge 93 with recessed section 99 to form a continuous floor 142. Equal features of the individual paving panels are labeled as indicated above. As previously described, various types of mesh shapes may be secured in the space defined by the bottom surface 100 of the expanded polymer panel92 and the exposed ends 108 and 110 and second transverse members 128 and 129 of the embedded metal bars 94 and 96. As non-limiting examples, the rectangular ventilation duct 147 is shown in figure 13 and the circular air duct 148 is shown in figure 14.

As shown in the embodiment of FIG. 13, the male and female wood floor 149 is placed over paving units 90 and attached to the first sleepers 124 and 126. In an alternative mode (not shown) a plywood, plastic, particulate board or other suitable subfloor can be attached to the first transoms 124 and 126 and the male and female wooden floor 149 attached to them.

As shown in Figure 3, one end of the inlaid metal bars 94 and 96 is seated and attached to one of the bars of rim 122 and a second bar of the bars is attached to the other end of the inlaid metal bars 94 and 96. A floor base 149, typically plywood, slabs of particulate material or other supporting surfaces or paving material may be attached to the first sleepers 124 and / or 126.

Referring to Figure 3, inlaid metal bars 94 and 96 have utility holes 127 spaced along their length. Deutability holes 127 are used to accommodate wiring for electricity, telephone, cable television, speakers and other electronic devices. Deutility holes 127 may have various transverse sectional shapes, non-limiting examples being round, oval, elliptical, square, rectangular, triangular, hexagonal or octagonal. The cross-sectional area of utility holes127 may also vary independently of each other, or they may be uniform. The cross-sectional area of utility holes 127 is limited by the dimensions of the inlaid metal bars 94 and 96, the deutility holes 127 will fit within their dimensions and will not significantly impair their structural integrity and strength. The cross-sectional area of utility holes 127 may be independently at least 1, in some cases at least 2, and in other cases at least 5 cm2 and may be up to 30, in some cases up to 25, in other cases up to 20 cm2. The cross-sectional area of utility holes 127 may be independently of any value, or may vary from any of the above values.

Expansion holes 113, mentioned above, are used where, as the expanded polymer body 92 is molded, the polymer matrix expands through the expansion holes 113 and the expanding opolymer melts. This allows a polymer matrix to engage and maintain embedded rafters 94 and 96 through expanding polymer fusion. In one embodiment of the invention, expansion holes113 may have a flanged surface and, in many cases, a laminated flange surface to provide greater resistance to the metal inlaid rafters.

In one embodiment of the invention, the paving system may be placed on a foundation. However, because foundations are rarely perfectly level, a level track can be attached to the foundation prior to laying the paving system. The level track includes an upper surface having a length and two side rails extending from opposite edges of the upper surface, where the width of the upper surface is greater than the width of the foundation and the length of the upper surface is generally about the same length as the foundation. . Level track is generally attached to the foundation by placing a level track over the foundation with the side rails generally making contact with the foundation sides, placing the upper surface so that it fits the level and permanently attaching a level track to the foundation .

A rim bar can be used to help attach the upper surface to one end of the plurality of composite floorboards.

More particularly, level track 128 may be attached to foundation 130 prior to laying the paving system (see figures 3 and 4). Level 128 track can be placed on foundation 128 and leveled. Level is made permanent by securing level 128 track to foundation 130 by using fasteners 131 (nails shown, although screws or other suitable devices can be used) through fixing holes 132. Screws 133 can also be used to attach level 128 track to foundation 130 through bolt holes 135. Some bolt holes135 may be used in conjunction with bolts 133 to attach a lower end of the hoop rim 122 to level track 128. Bolts 133 may also maintain the level position of level track 128 to to achieve a more permanent positioning. Alternatively or in addition to the mortar it may be applied by means of mortar holes 134 to fill the space between the level runway 128 and the foundation top 130. Once the level runway 128 has been attached and / or the mortar has sufficiently hardened Paving system can be stuck in the foundation.

Level track 128 includes side rails 137, which are adapted to extend over a foundation portion 130. The width of level track 128 is the transverse distance of the upper portion of level track 128 from one side rail 138 to another. Level 128 runway width is typically slightly larger than foundation width 130. Level 128 runway width can be at least 10 cm, in some cases at least 15 cm, in other cases at least 20 cm and in some instances at least. minus 21 cm. Also, the level 128 track width can be up to 40 cm, in some cases up to 35 cm, and in other cases up to 30 cm. The width of the level track 128 may be any value, or it may vary from any of the above values.

The length of the side rail 137 is the distance extending from an upper portion of the level runway 128 and is of sufficient length to permit proper leveling of the level runway 128 and attachment to the foundation 130 by means of fasteners 131 and fixing holes 132. The length of the side rail 137 may be at least 4 cm, in some cases at least 5 cm, and in other cases at least 7 cm. Also, the length of the side rail 137 may be up to 20 cm, in some cases up to 15 cm, and in other cases up to 12 cm. The length of the side rail 137 may be any value, or may vary from any of the above values.

One embodiment of the invention relates to an insulated precast or pre-cast panel for lifting, that is, adapted to act as a concrete beam formwork. As shown in Figure 15, beam panel I 140 includes expanded polymer formwork 142 (center body) and expanded metal elements 144 and 146 (recessed reinforcing bars). Expanded polymer formwork 142 includes openings 148 that traverse all or part of the length of the expanded polymer formwork 142. The expanded metal elements 144 and 146 have butt ends 152 and 156 respectively contact the inner face 150 of the expanded polymer form 142. The expanded metal elements 144 and 146 also have exposed ends 158 and 160 respectively which extend from the outer face 162 of the expanded polymer formwork 142.

Expanded polymer formwork 142 may have a thickness, measured as the distance from the inner face 150 to the outer face 162, of dimensions similar to those of the expanded polymer body 12.

Exposed ends 158 and 160 extend at least 1, in some cases at least 2, and in other cases at least 3 cm to the forced outer face 162 of expanded polymer form 142. Also, exposed ends 158 and 160 may extend to 60, in some cases up to 40, and in other cases up to 20 cm off the outer face 162 of the expanded polymer shape 142. Exposed ends 158 and 160 of any of the distances, or may vary between any of the above distances of the outer face 100.

In one embodiment of the invention, expanded metal members 144 and 146 have a cross-sectional shape including inlay lengths 164 and 166, inlay ends 152 and 156 and exposed ends 158 and 160. The orientation of expanded metal elements 144 and 146 is referenced by direction of open ends 168 and 170. In one embodiment of the invention, open ends 168 and 170 are oriented towards each other. In this embodiment, the beam panel 140 is adapted to be embedded in concrete that can be applied to the external face 162.

The spacing between each of expanded metal members144 and 146 can be described with respect to the embedded metal rafters 14 and 16th wall unit 10.

The openings 148 may have various cross-sectional shapes and similar spacing and cross-sectional area as described with respect to the openings 18 in the expanded polymer body 12.

As shown in Fig. 15, the expanded polymer panel 140 has a fixed length and has a flat end end 170 including front edge 172 and exit edge 174 and a receiving end 176 including recessed section 178 which is adapted to receive front edge 172 and projecting edge 180. Typically, beam lengths I panels 140 are interconnected by inserting a front edge 172 by a first beam panel I 140 into a recessed section 178 of a second beam panel I. Thus, a larger roof, roof, Paving or wall section containing any amount of beam panels I can be mounted and / or arranged. The beam width I 140, measured as the distance from the protruding edge 180 to the exit deck 174, may typically be at least 20, in some cases at least 30, and in other cases at least 35 cm and may be up to 150 in some cases up to 135, and in other cases up to 125 cm. The width of the beam panel I 140 may be any value, or may vary from any of the above values.

The beam panel I 140 includes beam channel I182. The present beam panel I is advantageous when compared to prior art systems where the connection between adjacent panels in the prior art is provided along the expanded polymer thin section below the channel of the beam. beam I 182. The resulting thin edge is prone to damage and / or breakage during transport and handling. The beam panel I of the present invention eliminates this problem by molding the beam channel I by eliminating the exposure of a thin edge section to potential damage.

In one embodiment of the invention, reinforcing bar or other concrete reinforcing rebar may be placed in the beam channel I 182a in order to increase strength and reinforce the notch formed concrete beam I of beam I 182.

In another embodiment of the invention shown in Figure 16, instead of beam channel 1182, beam panel 1141 includes channel 183. Channel183 is adapted to accept round duct networks or other mechanical and utility parts and / or may be filled with concrete superscripts.

An example of an I-beam system 200 according to the invention is shown in FIG. 17, where four I-beam panels 140 are connected by inserting the front edge 172 by a first beam panel 140 into a recessed section 178 of a second panel. Beam I. Concrete is cast, finished and fixed to form a concrete layer 202 which includes concrete beams I, which are formed into beam channels I182. The embodiment shown in figure 17 is an alternative embodiment where beam channel I 182 of each beam panel I 140 alternately faces concrete layer 202 and includes concrete beam I or faces away from concrete layer 202, and beam channel 182 contains no concrete. In one embodiment of the invention, the outwardly beamed panel may be beam panel 141. Alternatively, each beam panel I 140 may face concrete layer 202 and include concrete beam 204.

In the embodiment shown, the exposed ends 158 and 160 are both embedded in the concrete layer 202 and are exposed. The exposed ends 158 and 160 are available as attachment points for a finishing surface 210, which may include wood, rigid plastic, wood paneling, concrete paneling, cement paneling, plasterboard, plasterboard, particulate board, rigid plastic paneling , or any other suitable material with decorative and / or structural functions or other construction substrates 210. Attachment is typically accomplished by the use of screws, nails, adhesive or other fasteners known in the art.

In one embodiment of the invention, the beam system 200 is mounted on a flat surface and a first end is raised while a second end remains stationary, resulting in an overall beam system 200 perpendicular to the flat surface. This is generally referred to as a "preformed wall lift" and in this embodiment of the invention the beam system 200 is referred to as a "preformed wall lift".

In another embodiment of the invention, the beam system I200 may be used as a roof in a structure or a floor in a structure.

Embodiments of the present invention provide a composite construction panel comprising a substantially parallelepiped central body containing an expanded polymer matrix as described above having opposite faces, an upper surface and an opposite lower surface; at least one reinforced recessed rafter extending longitudinally through the central body between opposing faces, having a first end embedded in the expanded polymer matrix, a second end extending outwardly of the lower center body surface, and one or more recess holes. expansion members located in the inlaid rafter between the first end of the inlaid rafter and the bottom surface of the center body, where the center body contains a polymer matrix that expands through the expansion holes; and a concrete layer covers at least a portion of the upper surface and / or lower surface.

A particular embodiment concerns an insulated panel for lifting which is adapted for use as a wall panel or detector. As shown in Figures 13-21, single-sided wall panel 340 includes a reinforced body 341 including expanded polymer formwork 342 (center body) and expanded metal elements 344 and 346 (recessed reinforcement bars). Expanded polymer formwork 342 may include openings 348 that span all or part of the length of expanded polymer formwork 342. Expanded metal members 344 and 346 have recessed ends 352 and 356 respectively which are not in contact with the inner face 350 of the expanded polymer formwork. 342. Expanded metal elements 344 and 346 also have exposed ends 358 and 360 respectively extending from the outer face 362 of the expanded polymer form 342.

Expanded polymer formwork 342 may have a thickness, measured as the distance from the inner face 350 to the outer face 362, of similar dimensions to those of the expanded polymer body 12.

Exposed ends 358 and 360 extend at least 1, in some cases at least 2, and in other cases at least 3 cm to the forced outer face 362 of expanded polymer formwork 342. Also, exposed ends 358 and 360 may extend to 60, in some cases up to 40, and in other cases up to 20 cm off the outer face 362 of the expanded polymer shape 342. Exposed ends 358 and 360 may extend from any of the distances, or may vary between any of the unsubstantiated distances of the outer face 362.

In the embodiment of the invention, expanded metal members344 and 346 have a cross-sectional shape that includes inlay lengths 364 and 366, recessed ends 352 and 356, and exposed ends 358 and 360. The orientation of expanded metal elements 344 and 346 is referenced by direction. Recessed Ends 352 and 356. In the particular embodiment of the invention, Recessed Ends 352 and 356 are oriented towards each other. In this embodiment, single-sided wall panel 340 is adapted so that exposed ends 358 and 360 of expanded metal members 344 and 346 are embedded in concrete 370 or applied to outer face 362.

The spacing between each of the expanded metal elements 344 and 346 may be described with respect to the metal embossed rafters 14 and 16 to the wall unit 10.

In one embodiment of the invention, the humidified wall panel 340 includes expanded polymer body 342 (center body), expanded metal elements 344 and 346 (recessed reinforcing bars) including flanges 311, cornered ends 312, utility holes 346 located on an exposed portion of expanded metal members 344 and 346, expansion holes 313 in an embedded portion of expanded metal elements 344 and 346, and embedded ends 344 and 346, which do not touch the internal face 350.

In one embodiment of the invention, the inner face 350 may have a corrugated surface 351, which may be molded or cut-out, which improves air flow between the inner face 350 and any surface attached thereto.

Expansion holes 313 are used where, as expanded polymer body 342 is molded, the polymer matrix expands through expansion holes 313 and the expanding polymer melts. This allows a polymer matrix to surround and hold expanded metal elements 344 and 346 by melting into the expanding polymer. In the embodiment of the invention, expansion holes 313 may have a flanged surface and in many cases a laminated flange surface to provide greater resistance to expanded metal elements.

The openings 348 may have various cross-sectional shapes and similar spacing and cross-sectional area as described with respect to the openings 18 in the expanded polymer body 12.

The reinforced body 341 has a finite length and has a male end 371 that includes a receiving end 374, which includes a recessed section that is adapted to receive the edge 372. Typically, one-sided wall panel lengths40 are interconnected by inserting each other. a front edge 372 by a first side wall panel 340 in a recessed section 378 of a second side wall panel. In this way, a larger wall or ceiling section containing any number of one-wall wall panels can be mounted and / or arranged. The width of one-sided wall panel 340, measured as the distance from protruding edge 380 to exit edge 374, may typically be at least 20, in some cases at least 30, and in other cases at least 35 cm and may be up to 150, in some cases up to 135, and in other cases up to 125 cm. The width of one side wall panel 340 may be any value, or may vary from any of the above values.

An example of a one-sided wall panel 340 according to the invention is shown in Figures 20 and 21, where four expanded metal elements 344 and 346 are used. Concrete is cast, finished and fixed to form a concrete layer 370 which coats exposed ends358 and 360 of expanded metal members 344 and 346.

The recessed ends 350 and 356 of the expanded metal elements 344 and 346 are available as attachment points for a trim surface 375 such as wood, rigid plastic, wood paneling, concrete paneling, cement paneling, plasterboard, slab board, slabs of particulate material, rigid plastic panels, or any other suitable material with decorative and / or structural functions or other building substrates (shown in figures 20 and 21). Attachment is typically performed using screws, nails, adhesive or other fasteners known in the art.

In one embodiment of the invention, the humble wall panel 340 is mounted on a flat surface and a first end is raised, while a second end remains stationary, resulting in the orientation of the one side wall panel 340 generally perpendicular to the flat surface. This is generally referred to as "lifting a precast wall" in technology and, in this embodiment of the invention, single-sided wall panel 340 is referred to as a "raised precast wall".

In embodiments of the above-described raised precast walls, the exposed ends of the expanded metal members may act as a chair for the proper placement of the reinforcing wire mesh and / or reinforcing bar or other reinforcing rebar in the center of a concrete layer cast. , finished and hardened to coat exposed ends.

In embodiments of the above-described raised precast walls shown in Figure 21, the exposed ends 358 and 360 of the expanded metal members 344 and 346 may act as a chair for the proper placement of the reinforcing wire mesh 371 and / or reinforcing bar or other rebar. reinforcement in the center of a concrete layer 370, cast, finished and hardened to coat the exposed ends.

Another particular embodiment provides a composite construction panel where a first concrete layer covers at least one portion of the upper surface and coats at least one first end of an embedded rafter and a second concrete layer covers at least a portion of the lower surface and coats at least a second. end of a built-in rafter.

This particular embodiment of the invention may provide a second insulated panel for lifting which is adapted for use as a wall or ceiling panel. As shown in Figures 22-25, double-sided wall panel 440 includes a reinforced body 441 that includes expanded polymeric formwork 442 (center body) and expanded metal elements 444 and 446 (recessed reinforcing bars). Expanded polymer formwork 442 may include openings 448 that traverse all or part of the length of expanded polymer formwork 442. Expanded metal members 444 and 446 have a first opposite end 452 and second opposite end 456 respectively extending from first face 462 of the polymer formwork 442. Expanded metal elements 444 and 446 also have second exposed ends 458 and 460 respectively extending from the second face 450 of expanded polymer formwork 442.

Expanded polymer formwork 442 may have a thickness, measured as the distance from second face 450 to first face 462, of similar dimensions to those of expanded polymer body 12.

The exposed ends may extend at least 1, in some cases at least 2, and in other cases at least 3 cm beyond 450 as well as face 462 of the expanded polymer formwork 442. Also, the exposed ends may extend up to 60, in some cases up to 40, and in other cases up to 20 cm off any face of the expanded polymer form 442. Exposed ends may extend any distance, or may vary between any of the above distances of any face of the polymer form. expanded 442.

In one embodiment of the invention, exposed ends 452, 456, 458 and 460 are embedded in first concrete layer 469 and second concrete layer 470 which are applied to faces 450 and 462.

The spacing between each of the expanded metal elements 444 and 446 can be described with respect to the metal embossed rafters 14 and 16 in the wall unit 10.

In one embodiment of the invention, the double face wall panel 440 includes expanded polymer body 442 (center body), expanded metal elements 444 and 446 (recessed reinforcing bars), with corner ends 412, utility holes 446 located in an exposed portion of expanded metal elements 444 and 446, and expanding holes 413 in an embedded portion of expanded metal elements444 and 446.

Expansion holes 413 are used in which, as expanded polymer body 442 is molded, the polymer matrix expands through expansion holes 413 and the expanding polymer melts. This allows a polymer matrix to surround and hold expanded metal elements 444 and 446 by melting into the expanding polymer. In the embodiment of the invention, expansion holes 413 may have a flanged surface and in many cases a laminated flange surface to provide greater resistance to expanded metal elements.

The openings 448 may have various cross-sectional shapes and similar spacing and cross-sectional area as described with respect to the openings 18 in the expanded polymer body 12.

Reinforced body 441 is of imitation length and has a male end end 471 including front edge 472 and a receiving end 476 including recessed section 478 which is adapted to receive front edge 472. Typically, double-sided wall lengths 440 are interconnected. inserting a border 472 through a first double-sided panel wall 440 into a lowered section 478 of a second double-sided wall panel. In this way, a larger wall, floor, roof or ceiling section containing any amount of double-sided wall panels can be assembled and / or arranged.

The width of a single-sided wall panel 440, measured as the distance from the front edge 472 to the undercut section 478 may typically be at least 20, in some cases at least 30, and in other cases at least 35cm and may be up to 150 in in some cases up to 135, and in other cases up to 125 cm. The width of 440 double-sided wall panel can be any value, or could vary between any of the above.

An example of a double-sided wall panel 440 according to the invention is shown in Figure 24, where four expanded metal elements 444 and 446 are used. Concrete is cast, finished and hardened to form concrete layers 469 and 470 that coat exposed ends 452, 456, 458 and 460 of the expanded metal elements.

Alternatively, as shown in Figure 25, both exposed ends 452 and 456 and / or 458 and 460 are available as attachment points for a trim surface 475 such as wood, rigid plastic, wood panels, concrete panels, cement panels, wall plaster, plasterboard, particulate boards, rigid plastic panels, or any other suitable material with decorative and / or structural functions or other construction substrates. Attachment is typically accomplished by the use of screws, nails, adhesives or other fasteners known in the art. In this embodiment, the space 476 defined by the finished surface 475, the exposed ends 452 and 456 and the expanded polymer body 442 can be used to pass utilities, insulation and anchors for the above described interior finishes.

The present invention provides a method of constructing a building which includes mounting any of the superscript composite building panels on a generally flat surface, and raising a first end of the composite building panel, while a second end remains stationary, resulting in the orientation of the building panel to form a building. wall of the building.

In one embodiment of the invention, the double face wall panel 440 is mounted on a flat surface and a first end is raised, while a second end remains stationary, resulting in the orientation of the double face wall panel 440 generally perpendicular to the flat surface. This is generally referred to as "lifting a precast wall" in technology and, in this embodiment of the invention, double-sided wall panel 440 is referred to as a "raised precast wall".

In embodiments of the above-described raised precast walls shown in Figure 25, the exposed ends 458 and 460 of the expanded metal elements 444 and 446 may act as a chair for the proper placement of reinforcing wire mesh 471 and / or reinforcing bar or other reinforcements. Reinforcing rebar in the center of a layer of concrete 470, cast, finished and hardened to coat the exposed ends.

In one embodiment of the invention, when the exposed ends of the one-sided wall panel and double-sided wall panel are coated with concrete as described above, the deutility holes 346 and 446 act as places where fixed and hardened concrete melts through the holes and thus maintains and attaches the expanded metal elements. In addition, reinforcing rebar can be placed through utility holes 346 and 446 connecting the expanded metal elements, thereby further reinforcing the formed wall panel.

In the form used herein, the term "concrete" refers to a hard and sturdy construction material made by mixing a sufficiently hot water mix to make the cementitious mix settle to the entire mass as is known in the art.

In one embodiment of the invention, the concrete may be a so-called "low weight concrete" where low weight aggregate is included with the cementitious mixture. Exemplary lightweight concrete compositions that may be used in the present invention are disclosed in US Patents 3,021,291, 3,214,393, 3,257,338, 3,272,765, 5,622,556,5,725,652, 5,580,378 and 6,851,235, JP 9,071,449, WO 98 02 397, WO00 / 61519 and WO 01/66485, the relevant parts of which are incorporated herein by reference. The wall units, floor units, upwardly insulated panels and beam panels I described herein contain variations which shall not mean limitations. Any of the variations discussed in one embodiment may be used in another embodiment without limitation.

The embodiment of the invention shown in Figure 14 shows an example of using combinations of the composite panels described herein and combining features of the various panels. This embodiment combines beam panel I 140 and floor panel 92 (shown as 92 and 92A). In this embodiment, the receiving end 176 of the beam panel I 140 accepts the leading edge 93 of the floor panel 92 and the lowered section 99 of the floor panel 92A accepts the leading edge 172 of the beam panel I140 to provide male and female connections for establishing the continuous debaving system 141. In this embodiment, circular ductwork 148 is installed along the bottom surface 100 of the paving panel 92 between recessed metal bars 94 and 96. In this embodiment, the debaving material is concrete layer 145, which covers the surface. 102 of paving panels 92 and 92A and the outer face 162 of beam panel I140. The beam channel I 182 extends from the outer face 162 and is open to it and is filled with concrete and the concrete layer thickness 145 is sufficient to coat exposed ends 158 and 160 of the beam panel 140. The combination shown in this embodiment provides a insulated concrete paving system where utilities can pass under an insulating layer.

In one embodiment of the invention, a batten may be attached to the exposed ends of the metal rafters, metal bars or metal elements of the wall units, paving units and expanded polymer panels; that is, building elements of the invention. The batten is capable of supporting a cover layer consisting of a suitable construction material. The batten may include one or more portions extending flush with opposite side sides of the building element, which may be embedded and anchored in the concrete used to incorporate and / or join one or more adjacent building elements.

The batten may support one or more layers of cover and typically a stretched metal batten including a rhombohedral mesh having a rhombohedral ratio of length to about 2: 1. The length of the rhombus may vary between 20 and 60 mm, while the diamond length may vary between 10 and 30 mm. The drawn metal batten may have a thickness of 0.4 to 1.5 mm and in some cases 0.4 to 1.0 mm.

The cover layers may include one or more mortar, plaster, cement coating layers such as they are or, optionally, fiber reinforced of a suitable material.

In one embodiment of the invention shown in Figure 29, the outer surface 24 of the expanded polymer body 12 may have any desirable surface type. In some instances the outer surface 24 will be smooth, in other instances notches may be cut or molded into the outer surface 24, in other cases the outer surface 24 may have long ridges to facilitate air flow, and in particular cases as shown in the figure 29, the outer surface 24 may be adapted to accept plaster. In order to facilitate the application of plaster to external surface 24, T 1300 slots may be cut or molded to external surface 24. Any suitable type of plaster may be used, non-limiting examples including natural material plaster or polymer-based plaster. T 1300 slots in the outer surface 24, a plaster-ready panel surface is provided. More particularly, T 1300 slots provide a mechanical connection for plaster adhesion and no secondary mesh is required. In the particular embodiment of the invention, T 1300 slits allow the use of natural material plaster, as this type of plaster powers and does not trap moisture. When plaster is applied to an external surface 24, T 1300 slots may be used as water condensation channels or for other finishing techniques.

A particular advantage of building panels, wall units, paving units and expanded polymer panels according to the invention relates to fire protection and safety. As described above, a portion of the embedded frame rafters or support bars of the recessed floors is exposed and may include a membrane of holes formed along its length.

By exposing a section of the hole membrane in the embedded frame rafters or underfloor support bars, airflow is encouraged and, in the event of fire, the section of the embedded frame rafters or underfloor support bars cool down. This may be very important to prolong the failure time of a loaded wall section. Typically, in a fire test, a metalisable rafter will be refused in the central membrane area.

Location extension bars, previously described in the exposed membrane section, the built-in frame rafters or built-in floor support rods act as a heat sink, helping to dissipate heat from the central membrane section of the built-in rafters or support bars of the built-in floors. as aiding in the structural properties of the wall.

The fusion properties of the polymer matrix in case of fire additionally facilitates the cooling of the membrane section of the inlaid frame rafters or underfloor support bars by melting the membrane as the temperature exceeds 200 ° F (93.3 ° C), allowing additionally air circulation and membrane cooling.

The lower runway of the wall panel, as described above, can be designed to act as a ping pong and containment in the event of fire. The lower runway area is designed to contain the solids that melt when the polymer matrix burns out. The lower piston is adapted to contain a volume at least equivalent to the volume of the expanded polymer matrix in the expanded or melt-expanded polymer body. Each track section can be designed to have a holding capacity of at least 0.2 ft3 (5.66 dm3), in some instances at least 0.25 ft3 (7.08 dm3), in some cases at least 0.3 ft3 ( 8.5 dm3) and in other cases at least 0.4 ft3 (11.33 dm3) and the containment capacity can be up to 0.75 ft3 (21.24 dm3), in some cases up to 0.65 ft3 (18, 41 dm3) and in other cases up to 0.1 ft3 (2.83 dm3) of molten or liquid material. The containment volume in a lower lane may be any value, or may vary between any of the above values. Lower runway containment capacity is typically designed to contain solids contained in a typical 48 "x 96" (1.22 m x 2.44 m) building panel.

In larger building panels, for example, those of higher height, the outer portion of the lower runway may be knurled, which allows the evacuation of molten materials to the exterior of the building. This design greatly reduces the spread of the interior fire and improves the safety of the interior environment of the structure during initial fire spreading and rescue operations.

Embodiments of the present invention provide for permanent insulating concrete formwork system in place, i.e. continuous nature, with length being limited only by transport and handling restrictions. The present insulating concrete formwork system comprises two opposite expanded plastic faces internally connected and spaced apart by perforated metal structural members. The expanded plastic faces and metal spacing elements are aligned with the formwork to position the proper concrete reinforcement steel vertically and horizontally, while also allowing proper concrete flow and functional finishing attachments. The cast steel structural elements act as the inner arm, keeping the forms straight and aligned during the placement of the concrete, eliminating the need for most external locking.

Additionally, the present invention provides preformed isolated deconcrete forms which include one or more longitudinally disposed structural members or reinforcement bars, the ends of which are at least partially expanded facing polymer bodies embedded in one another. The remainder of the reinforcing structural member (s), the portion between the expanded polymer bodies, is at least partially exposed. The end portions that are encapsulated in the expanded polymer matrix may provide a thermal breaker from the external environment.

Reinforcing structural members can be flanged lengthwise on either side to provide attachment points for objects external to the panel. Perforations in the reinforcing structural members at the end portions that are encapsulated in the expanded polymer matrix allow fusion of the perpendicularly expandable polymer particles. Perforations in the exposed portions of the structural reinforcement element provide attachment points for lateral attachment and / or reinforcement bar and allow uniform concrete flow when concrete is cast into the present insulated concrete formwork. The male and female or overlap connection point provides panel support while maintaining the integrity of the concrete formwork. Longitudinal holes may be arranged in the expanded polymer matrix and may be of varying diameter and location to provide areas for utility placement, making the structure and channels for venting gas lighter. Fabrication of the panel is by the use of a semicontinuous or continuous molding process which permits varying panel lengths. The embedded rafters used in the invention may be made of any suitable material described above. In a particular embodiment of the invention, the inlaid rafters are made of a thin metal.

The embedded rafters may have a thickness as described above. The thickness of the embedded rafters will depend upon the intended use of the preformed construction panel.

In the embodiment of the invention, the embedded rafters have holes or openings along their length to facilitate fusion of the expanded plastics material and to reduce any thermal bonding effect on the bars, rafters, bars and / or reinforcing elements.

In the present invention, the expanded plastic faces may be molded from any suitable expandable material plastic, as described above, in a molding machine capable of inserting the metal elements and forming two opposing face panels, while maintaining the composite materials in their relative positions at each other. a continuous or semicontinuous process.

In a particular embodiment of the invention, expandable thermoplastic particles are expandable polystyrene (EPS) particles. These particles may be in the form of beads, granules, or other particles suitable for the aforementioned expansion and molding operations.

More particularly, the present isolated concrete formwork includes a substantially parallelepiped first body containing an expanded polymer matrix having opposite faces, a first surface and a second opposite surface; a second body, substantially parallelepiped in shape, containing an expanded polymer matrix having opposite faces, a first surface, an opposite second surface; and one or more inlaid rafters extending longitudinally through the first body and the second body between the first surfaces of each body, having a first end embedded in the expanded polymer matrix of the first body, and a second end embedded in the expanded polymer matrix of the second body. One or more expansion holes are provided in the embedded rafter portion embedded in the first body and the second body. The first body and the second body include a polymer matrix that expands through the expansion holes. The space defined between the first surfaces of the first body and the second body is capable of accepting concrete cast into it.

One embodiment of the present invention provides isolated deconcrete forms (ICF) and ICF systems. As shown in Figure 30, ICF510 includes first expanded polymer body 511 and second expanded polymer body 512, left-facing embedded metal rafters 514, and right-facing embedded metal rafters 516 (reinforced recessed bars). Recessed metal rafters 514 and 516 have recessed ends 520 and 522 respectively that do not touch the outer surface 524 of expanded polymer first body 511. Recessed metal rafters 514 and 516 have recessed ends 521 and 523 respectively that are adjacent to the outer surface 525 of the second corpode. expanded polymer 512. Space 505 is defined as an inner subsurface space 530 of the first expanded polymer body 511 and the inner surface 531 of the second expanded polymer body 512 to the height of the ICF 510.

expanded polymer bodies 511 and 512 may have a thickness, measured as the distance from the inner surface 530 or 531 respectively to the outer surface 524 or 525, respectively, at least 2, in some cases at least 2.5, and in other cases by minus 3 cm and may be up to 10 cm, in some cases up to 8 cm and in other cases up to 6 cm from the inner surface 30 of the expanded polymer body 512. The thickness of the expanded polymer body 511 and 512 may be independently of any size, or may vary between any size. of the above dimensions.

Recessed ends 520 and 522 extend at least 1, in some cases at least 2, and in other cases at least 3 cm within the expanded polymer body 512 off the inner surface 530. Also, the embedded ends 520 and 522 may extend up to 10, in some cases up to 8, and in other cases up to 6 cm off the inner surface 530 within the first expanded polymer body 511. Embedded ends 526 and 528 either of the distances, or may vary between any of the above-mentioned inner surface distances 530 inside the polymer body 511.

In another embodiment of the invention, the butt ends 520 and 522 may extend from 1/10 to 9/10, in some cases 1/3 to 2/3 and in other cases 1/4 to 3/4 of first body thickness. of expanded polymer 511 into the expanded polymer body 511.

The orientation of the inlaid metal rafters 514 and 516 is referenced by the direction of the ends 520, 521, 522 and 523. Endpoints can be oriented in any direction that suits the strength, attachment objectives, or stability of the insulated formwork.

The spacing between each of the inlaid metal rafters 514 and 516 is typically adapted to be consistent with local building codes or methods, but may be modified to suit special needs. As such, the spacing between metal rafters may be at least 10, in some instances at least 25 and in some cases at least 30 cm and may be up to 110, in some cases up to 100, in other cases up to 75, and in some instances up to 60 cm. The spacing between embedded metal rafters 514 and 516 may be any distance, or may vary between any of the aforementioned distances.

ICF 510 may extend over a distance with recessed recessed demetal rafters 514 and 516 placed therein. The length of the ICF510 can be any length that allows safe and minimal handling on the ICF 510. The length of the ICF 510 may typically be at least 1, in some cases at least 1.5, and in other cases at least 2 m and may be up to 25, in some cases up to 20, in other cases up to 15, in some occurrences up to 10 and in others up to 5 in. The length of the ICF510 can be any value, or it can vary from any of the above values. In some embodiments of the invention, each end of the ICF510 ends with a built-in metal rafter.

The height of the ICF 510 may be any height that allows safe handling, minimal damage and can withstand the pressure of the cast within the ICF 510. The height of the ICF 510 may be at least 1 and in some cases at least 1.25 m and may be up to 3 M and in some cases up to 2.5m. In some instances, in order to increase the stability of the ICF510 unit, reinforcing crosspieces or reinforcing bar (not shown) may be attached to the embedded metal rafters 514 and 516. The height of the ICF 10 may be any value, or may vary between any of the above values.

The space 505, the space between inner surface 530 and inner surface 531 for the height of ICF 510, can be any suitable volume and / or dimensions. Suitable volume and / or dimensions are those where the weight of concrete poured into space 505 is not so high as to cause any part of ICF 50 not to support, that is, to allow the concrete to compress through ICF 510 such that the volume concrete not enclosed in space 505, but large enough that the poured and poured concrete can withstand whatever is to be built into the resulting ICF deconcrete wall. Thus, the distance between the inner surface 530 and the inner surface 531 taken at the height defined above may be at least 5, in some cases at least 12 cm and may be up to 150 cm and in other cases up to 120 cm. In some instances, in order to increase the stability of the ICF 510 unit, reinforcing crosspieces or reinforcing bar (not shown) may be attached to the inlaid metal rafters 514e515. The distance between inner surface 530 and inner surface 531 may be any value, or may vary. between any of the above values.

In a particular embodiment of the invention, ICF 510 may be used as a storm wall. In this embodiment, the space 505 is filled with concrete as described herein, and the distance from the inner surface 530 to the inner surface 531 may be at least 2, in some cases at least 5 and in other cases at least 10 cm, and may be up to 16 inches. , in some cases up to 14 cm and in other cases up to 12 cm. In this storm wall mode, the distance between the inner surface 530 and the inner surface 531 may be any value, or may vary between any of the above values.

Storm walls made in accordance with the present invention may be used as any of the other raised precast wall panels and walls described herein.

As shown in Figure 30, ICF 510 has a finite length, and the first body 511 and second body 512 have an inner ferrule end 517 and an outer ferrule end 518.

Typically, ICF 510 lengths are interconnected by inserting an inner ferrule end 517 of one ICF 510 adjacent an outer ferrule end 518 of another ICF 510 to form a continuous ICF. Thus, a larger ICF containing any number of ICF units It can be assembled and / or arranged.

An alternative embodiment of the invention is shown in Figure 31, wave ICF 508 is similar to ICF 510 except that the inner body surface 530 511 and the inner surface 531 body 512 include opposite inner arched sections 532 and 534 respectively. Internal arcuate sections 532 and 534 provide nonlinear space within the ICF 508, so that concrete cast in the ICF 508 has sections that have larger transverse sectional width and sections that have a smaller cross-sectional width.

In another embodiment of the invention shown in Figure 32, ICF 509 has exposed ends 536 and 538 rather than embedded ends 521 and 523. Exposed ends 536 and 538 extend at least 1, in some cases at least 2, and in other cases at least minus 3 cm out of the outer surface 525 of the second expanded polymer body 512. The exposed ends 536 and 538 can be used to attach finishing surfaces such as plasterboard, plywood, paneling, etc. ICF 509. Also, exposed ends 536 and 538 may extend to 60, in some cases up to 40, and in other cases up to 20 cm off the outer surface 525 of expanded polymer body 512. Exposed ends 536 and 538 may extend either at any distance, or may vary between any of the aforementioned distances from the outer surface 525.

Referring to FIG. 32, inlaid metal rafters 514 and 516 may have utility holes spaced along their length between the outer surface 525 and exposed ends 536 and 538. The deutility holes (not shown here but previously described and illustrated) are used. to accommodate utilities such as wiring for electricity, telephone, cable television, speakers and other electronic devices, gas lines and hydraulic lines. Utility holes may have various cross-sectional shapes, non-limiting examples being round, oval, elliptical, square, rectangular, triangular, hexagonal or octagonal. The cross-sectional areas of utility holes may also vary independently of each other, or they may be uniform. The cross-sectional areas of the utility holes are limited by the dimensions of the inline metal rafters 514 and 516, but the utility holes will fit their dimensions and will not significantly impair their structural integrity and strength. The cross-sectional area of the utility holes may be independently at least 1, in some cases at least 2, and in other cases at least 5 cm 2 and may be up to 30, in some cases up to 25, in other cases up to 20 cm 2. The cross-sectional areas of the utility holes may independently be any value, or may vary between any of the above values.

In one embodiment of the invention, utility holes may have a flanged surface and, in many cases, a flanged surface to provide greater resistance to embedded metal rafters.

Figures 33 and 34 show features of the present ICF relating to ICF 508 (figure 31). A feature of the 514 and 516 metal insert rafters is that they may include expansion holes 540 and spill holes 542. As such, spill holes 544 may be a punched hole extending along the vertical axis of metal insert rafters 514 and / or 516 which is positioned to permit normal free flow of concrete and to secure and position horizontal concrete reinforcements. Similarly, expansion holes 540 may be a sufficiently sized punch hole or sufficient void slot to permit fusion.

and flow of the polymer matrix through the formed plastic panel.

The low-thickness metal structural members, inlaid metal rafters 514 and 516, can be continuously or semicontinuously formed to create an unlimited length composite panel. The metallic structural elements are strategically punctured along the external vertical axis to provide 540 expansion holes, which allow the flow and fusion of expandable plastic materials through the metallic elements. The central vertical axis of the metal element is punctured to provide 542 pour holes, which allow normal free flow of concrete and allow for the clamping and placement of horizontal concrete reinforcement materials. Figures 35 and 36 show a formed and fixed concrete 550 with respect to the metal-embedded rafters 514 and 516.

The recessed ends 521 and 523 continuous roofing strips that are arranged vertically at predetermined centers to assist in direct connection of finishing materials, top and bottom structural runways, wall penetrations, and roof and floor connection points, such as the level runway described herein. .

Expandable plastic materials in the panel composite act as a forming panel when concrete is placed in the formwork and also provides insulation and acoustic damping. Additionally, the expandable plastics material face of the composite panel acts as a deformation panel when concrete is placed in the formwork and also provides insulation and acoustic damping.

The present ICF design provides both horizontal and vertical concrete and vertical concrete paths created by the two opposite panels fixed by the low thickness structural elements.

When concrete is cast into space 505 of this ICF, an internal concrete assembly is formed by the two opposing panels in the vertical upstream wall configuration of the panel design. The concrete core created in the formwork acts as a horizontal clamp for the low-thickness metallic structural elements in the present ICF. In the upright wall panel design the concreting core allows horizontal reinforcement along the vertical upright axis created between the form face panels.

In the present ICF, the self-sealing self-aligning inner ferrule 517 and outer ferrule 518 locking panel ends securely connect one side panel termination to the other end of the panel side termination, forming a continuous horizontal discrete placement form as well as continuous vertical.

Figure 37 shows an embodiment of the invention where the surface of the steel member 560, which can be used as metal embossed rafters 514 and / or 516 in the present ICF, forms a hole 565 in opposite directions, creating a surface that increases concrete adhesion. and prevents cracking of concrete in contact with steel element 560. The effect of hole formation on the element surface increases steel shear strength and concrete composition. The forming of holes in the steel surface creates a stronger connection between the foam, and the steel element of the plastic foam faces the panel when molded as a composite structure.

Figure 38 shows an insulated concrete formwork system 575 for providing a foundation that includes a plurality of ICF's 508 connected end to end to form the ICF 575 system. Corner unit 552 is used to interconnect parallel ICF lines 554 perpendicular ICF lines 556. Concrete It is launched into space 505 of the 575 ICF wall system and cured to form a complete insulated concrete wall system.

The corner unit 552, shown in Fig. 39, essentially includes a first ICF 508A and a second ICF 508E (same features are enumerated as above) oriented at an angle with the first ICF 508A, where the corner section 562 is molded to include the first ICF. 508A and second ICF 508E to form a continuous first and second body and provide a continuous space 505 between them.

Referring to Figure 32, the particular advantages of ICF 509 include the ability to easily pass utilities prior to attaching a finishing surface to the exposed ends of the embedded metal rafters. Exposed metal rafters facilitate changes and additions of structural framing in the field and leave the joint structural parts exposed for local public inspectors to inspect the frame.

A defined utility space outer surface 525 of expanded polymer body 512 and exposed ends 536 and 538 may be adapted to accommodate utilities. Typically, the exposed ends 536 and 538 have a finishing surface attached to them, one side of which further defines the utility space.

In one embodiment of the invention, the utility space is adapted and sized to receive standard and / or prefabricated components such as windows, doors and medicine cabinets, as well as individualized cabinets and shelves.

Additionally, the air gap between the outer surface of the expanded polymer body 512 and the finishing surface allows for better air circulation, which can minimize or prevent mold formation. Moreover, because the metal rafters are not in direct contact. With the external environment, thermal bonding through highly conductive metal embeded rafters is avoided and insulation properties are improved.

The various embodiments described herein contain variations that should not mean limitations. Any of the relevant variations discussed in the ICF paneling, construction, paving, ceiling, wall and / or roofing arrangements may be used in the ICF paneling, construction, paving, ceiling, wall and / or roofing arrangements described herein without limitation.

In one embodiment of the invention, a batten may be attached to the exposed ends of the ICF metal rafters, metal bars or metal elements of the invention. The batten is capable of supporting a cover layer consisting of a suitable construction material. The paragraph may include one or more portions extending flush with opposite sides of the building element, which may be embedded and anchored in concrete used to incorporate and / or join one or more adjacent building elements.

The batten may support one or more cover layers and typically a stretched metal batten including a urombohedral forming mesh having a rhombohedral ratio of about 2: 1 in length. The length of the diamond may vary between 20 and 60 mm, while the width of the diamond may vary between 10 and 30 mm. The drawn sarrafometallic may have a thickness of 0.4 to 1.5 mm and in some cases 0.4 to 1.0 mm.

The cover layers may include one or more mortar, plaster, cement coating layers such as they are or, optionally, fiber reinforced of a suitable material.

In one embodiment of the invention, referring to Figures 3 and 38, insulated concrete formwork system 575 is to foundation 130, where level 128 piston is attached to it in the manner described above. In addition, the invention provides buildings including the present one. insulated concrete formwork as a foundation, with an optional level runway according to the invention attached thereto, and one or more floor panels, flooring systems, wall panels, wall systems, raised precast walls, storm panels , ceiling and / paneling panels as described herein. In the particular embodiment of the invention, paving panels, paving systems, wall panels, wall systems, raised precast walls and / or storm panels may be attached to the insulated concrete formwork system, optionally using the present level track. In addition to this particular embodiment, the present roof and / or roof panels may be attached to one or more of the present wall panels, wall systems, raised precast walls and / or storm panels. Thus, an unprecedented building is provided. The ICF units of the present invention may be made using an apparatus for shaping a continuous or continuous expanded plastic element which includes:

a first mold including:

(i) a lower wall, a pair of opposite side walls and

a lid, and

ii) a molding seat having the shape that matches the element defined in the mold between the side walls, the bottom wall and the cover;

a second mold including:

(i) a lower wall, a pair of opposite side walls and

a lid, and

ii) a molding seat having the shape that matches the element defined in the mold between the side walls, the bottom wall and the cover;

b) means for displacing the lid and mold sidewalls in favor of and against the bottom wall to longitudinally close and respectively open the mold; and

c) first means for adjustably positioning the lid for and against said lower mold wall for adjustable and substantially continuous control of the height of the molding seat.

The apparatus is configured to include reinforcing elements, recessed metal bars, recessed metal rafters, expanded metal bars, and expanded metal elements configured in the manner discussed above. As a non-limiting example, the methods and apparatus disclosed in U.S. Patent 5,792,481 may be adapted to make the ICF units of the present invention. Relevant parts of U.S. Patent 5,792,481 are incorporated herein by reference. The expanded polymer wall units, flooring units and panels of the present invention may be made using batch form molding techniques. However, this approach can lead to inconsistencies and can be very time consuming and expensive.

In the embodiment of the invention, the wall units, ceiling units, roof units, floor units and expanded polymer panels of the present invention may be made using an apparatus for molding a semicontinuous or continuous expanded plastic element which includes:

a) a mold including:

(i) a lower wall, a pair of opposite side walls and

a lid, and

ii) a molding seat having the shape that matches the element defined in the mold between the side walls, the bottom wall and the cover;

b) means for displacing the lid and the sidewalls of the mold for and against the bottom wall for longitudinally closing and respectively opening the mold; and

c) first means for adjustably positioning the lid for and against said lower mold wall for adjustable and substantially continuous control of the height of the molding seat.

The apparatus is configured to include reinforcing elements, recessed metal bars, recessed metal rafters, expanded metal bars, and expanded metal elements configured in the manner discussed above. As a non-limiting example, the methods and apparatus disclosed in U.S. Patent 5,792,481 may be adapted to make the expanded polymer wall units, floor units and panels of the present invention. Relevant parts of U.S. Patent 5,792,481 are incorporated herein by reference.

In one embodiment of the invention, the reinforcing elements, inlaid metal rafters, expanded metal bars and / or expanded metal elements 220 may be cast as wall units, paving units and expanded polymer panels having a built-in end 222 and end. exposed straight line 224 shown in figure 26. Subsequently, the opposite straight end may be formed, worked and / or modified to provide a shaped end 228A shown in the shaped element 226A in figure 27 or a shaped end 228B shown in the shaped element 226B in figure 28. Embedded Ends 226A and 226E may remain unchanged from a recessed end 222. Equipment and machinery for subsequently bending, working, forming or modifying the opposing end are well known in the art.

In one embodiment of the invention, the inner surface, bottom surface, or inner face of the above-described wall units, deburring units, and expanded polymer panels may have a notched surface, either molded or mechanically applied, to improve air flow through the annular space between the Expanded plastic like any materials attached to the exposed ends of the metal rafters, metal bars, or metal elements of the above-described wall units, deburring units, and expanded polymer panels.

The present invention relates to a method of constructing a building in a first embodiment including: providing a foundation having a series of upper surface walls, which may include the present isolated deconcrete formwork system;

positioning and securing the composite construction panels described above adapted for use as a paving unit and / or paving panels or paving systems in the manner described herein, such that the paving unit, panel and / or system covers at least a portion of the upper surfaces of the foundation walls;

position and secure any of the prescribed wall systems on the paving unit or system; and

position and secure a roof system described above on an upper surface of the wall system.

Another embodiment of the invention provides a method of building a building including:

providing a foundation having a series of foundation walls having upper surfaces, which may include the present insulated concrete formwork system;

positioning and securing the composite construction panels described above adapted for use as a paving unit and / or paving panels or paving systems in the manner described herein, such that the paving unit, panel and / or system covers at least a portion of the upper surfaces of the foundation walls;

positioning and securing two or more of the composite construction panels and / or storm panels described above adapted for use as a wall unit on at least part of a surface above the paver unit, wherein a lower track and an upper sliding track are attached to a lower end and upper end respectively of composite building panels, and

positioning and securing the composite building panels described above adapted for use as a roof unit by minus part of the upper sliding track of the wall units. In addition to this embodiment, a method of building the multi-floor building is provided which further includes:

positioning and securing the composite construction panels described above adapted for use as a second paving unit or system to at least a portion of the upper sliding track of the wall units; and

positioning and securing two or more of the previously described composite construction panels and / or storm panels adapted for use as a second wall unit on at least part of an upper surface of the second floor unit, wherein a lower piston and an upper sliding track are attached to a lower end and an upper end respectively of the composite construction panels;

where the roof unit is secured to at least part of the upper sliding track of the second wall units.

Thus, the present invention also provides a building containing one or more of the paving units, wall systems and roof systems described above.

The expanded polymer wall units, flooring units and panels of the present invention provide numerous advantages. For example, they virtually eliminate the need for resistive barriers. The expanded polymers used in the present invention typically have at least a rating equivalent to those required by local building codes for resistive barriers.

Also, no subcontractors are required during construction, as the expanded polymer wall units, paving units and panels of the invention already include suitable insulation. Construction materials also effectively block low frequency sound waves from outside noise. The acoustic properties of building panels, wall units, floor units and expanded polymer panels according to the invention are particularly advantageous. Typically, metal rafter structures have greater acoustic or sound transmission problems. Metal rafters generally do not amplify sound because of their ability to vibrate. When metal rafters are encapsulated in the polymer matrix, vibration is reduced resulting in lower vibration and desirable acoustic and sound transmission properties.

Additionally, less construction site structure is required due to the prefabricated nature of the present expanded polymer wall units, paving units and panels.

The generally shorter construction time resulting from the use of the present expanded polymer wall units, flooring units and panels allows for earlier closure and protection of the elements, leading to less water damage during construction. In addition, the holes, openings, ducts, notches, and spaces provided in the present expanded polymer wall units, paving units, and panels result in faster wiring and plumbing, and less scrap on the jobsite.

The present invention also relates to a method of doing business which allows an architectural design layout to be accessed by the apparatus for shaping a semicontinuous or continuous expanded plastic element to individualize the size, shape and dimensions of the various elements of building panels. , wall units, flooring units and expanded polymer panels of the invention. The architectural design layout can be provided through a disk software or through an Internet connection. For customers with Internet capabilities, access to this method is convenient and provides an efficient and fast method of designing and manufacturing building units and / or houses. In a non-limiting exemplary embodiment, a customer selects an architectural project for a building. The architectural design includes the unique features of each composite building panel to be used in the building. The architectural design is loaded into a processing unit that translates the drawing into instructions for the appliance to shape a semicontinuous or continuous expanded plastic element. The instructions direct the device to continuously or semicontinuously shape above-described panels and which individualization features to include in each panel.

The architectural design may include, by way of non-limiting examples, the dimensions and location of the openings and holes required in each reinforced recessed rafter, as well as any recess in each composite construction panel required to construct the building; the dimensions of each composite building panel to include thickness, width, height, spacing between embedded members, dimensions and shape for each embedded member, any channel that has to be cut or formed in the central body of each composite building panel, any of design features described above, any other features unique to each composite building panel, as well as ridge ends that accommodate any roof pitch or pitch, bay window floor cutouts, and other project-specific architectural features.

The processing unit may be any computer or device capable of reading instructions and translating them into instructions for the apparatus to mold a semicontinuous or continuous expanded plastic element.

Individualization features may include any of the above-described architectural design features. As a non-limiting example, individualization features may include forming the straight exposed end as shown in Figure 26 at a patterned end shown in either Figure 27 and 28. In another embodiment of the invention, an interactive computer program may be used. to provide the above-described architectural designs. In the embodiment of the invention, the architectural design can be fed using a series of computer screen menus, where a user selects options available on a computer screen. When the draw button is selected, a screen appears for additional choices for modifying the center body, the built-in frame rafters or built-in floor support bars and / or the spatial relationship between the two. Selecting any of the menus directs you to another screen where architectural design features described above can be fed, as well as the number of required panels that have these features. Upon selection, additional individualized panels can be fed. The user then checks the order by selecting an "order panels" button. Instructions are then transmitted to the apparatus for shaping a semicontinuous or continuous expanded plastic element and each of the various panels required having each of the project's architectural features are molded and cut to order specifications. In the embodiment of the invention, all panels are automatically labeled and marked for placement in their proper positions.

In an additional embodiment, the customer requests access to an interactive program that steps them through the design process. Once the drawing is complete, the customer can save the drawing for future use. The customer may also prefer to save the drawing for an order.

Using a drawing program on a website benefits the manufacturer in a variety of ways including a method used to obtain customer profiles that can be subsequently mailed, etc. In addition, a website that includes this unique method has worldwide reach and generates manufacturer name recognition, particularly where the building panel manufacturer is the only manufacturer to offer an affordable and convenient method of designing and ordering panels. of composite construction.

The design program of the invention provides an advantage to the user in his own business in that he enhances the user's professionalism by allowing prompt and immediate service to his own customers. For example, the customer may take a sketch or layout of an architectural project from a composite building panel store that requests building panels for use in the layout or project. In response, the panel shop owner, that is the user, can use the drawing program to construct a series of composite building panels on a computer screen with the customer by his side, and explain to the customer the benefits of individualized composite building panels. This process provides top-notch customer service, eliminates guesswork, enhances interaction between the panel shop and end customer and enhances the business reputation in the field.

Fig. 40 illustrates a method of doing business 400 between a composite building panel manufacturer 420 and a customer 414, 416 requiring individualized composite building panels. A composite building panel design program is provided to a client 414, 416 by means of a physical copy 418, for example, a disk containing a copy of the program, or by electronic access, for example, the Internet or mail. electronic. Composite building panel drawing software is used by a customer on a customer's personal computer 414, 416. The customer draws one or more composite building panels and delivers the complete drawing to manufacturer 420. The drawing can be printed to provide a physical copy 418 to manufacturer 420. In the particular embodiment of the present invention, the finished design is transferred to a central computer 406 located in manufacturer 420. In another particular embodiment, compatibility between the design program software and the software of the Apparatus for shaping a semicontinuous or continuous expanded plastic element 408 allows finished design specifications to be fed into apparatus 408 directly via a connection to the central computer. In another embodiment, the design specifications are manually fed to an operator of the apparatus. Drawing software stores and sorts data based on the particular drawing of panel types and identifies the most efficient sequence for making panels. Thus, software is used as a management tool to simplify the operator's work, including specifying the order of manufacture of the panels and how to maneuver the parts of the apparatus to switch from one panel design to the next. The method of doing business illustrated in Figure 40 reduces the time and cost of designing and manufacturing individualized building panels.

The present invention has been described with specific reference to its particular embodiments. Such details are not intended to be construed as limiting the scope of the invention except to the extent that they are included in the appended claims.

Claims (39)

1. Composite constructional panel comprising: a substantially parallelepiped central body comprising an expanded polymer matrix having opposite faces, an upper surface and an opposite lower surface, at least one structural inlaid rafter extending longitudinally through the central body between said opposing faces having a first end embedded in the expanded polymer matrix, a second end extending outwardly of the lower surface of the central body, and one or more expansion holes located in the rafters recessed between the first end of the recessed rafter and the lower surface of the central body, wherein the central body comprises a polymer matrix that expands through the expansion holes; a concrete layer covering at least a portion of the upper surface and / or lower surface. Composite paving panel, characterized in that it comprises: a substantially parallelepiped central body comprising an expanded polymer matrix having opposite faces, an upper surface and an opposite lower surface; one or more downwardly supporting floor members extending longitudinally through the central body between said opposing faces, having a first end embedded in the expanded polymer matrix having a first transverse element extending from the first end generally making contact or extending above the upper surface, a second end extending outwardly of the lower surface of the central body having a second transverse member extending from the second end, and one or more expansion holes located in the rafter embedded between the first end of the embedded rafter and the lower surface of the central body, wherein the central body comprises a polymer matrix that expands through the expansion holes, wherein the space defined by the lower surface of the central body and the second ends of the embedded bars is adapted to accommodate utility lines; and wherein the composite floor panel is positioned generally perpendicular to a structural wall and / or foundation. An isolated concrete formwork comprising: a substantially parallelepiped first body comprising an expanded polymer matrix having opposite faces, a first surface and a second opposite surface; a substantially substantially parallelepiped second body comprising an expanded polymer matrix having opposite faces, a first surface, a second opposite surface; one or more inlaid rafters extending longitudinally through the first body and the second body between the first surfaces of each body, having a first end embedded in the expanded polymer matrix of the first body, and a second end embedded in the expanded polymer matrix of the first body. second body, one or more expansion holes located in the embedded rafter portion embedded in the first body and the second body; wherein, the first body and the second body comprise a polymer matrix that expands through the expansion holes; and the space defined between the first surfaces of the first body and the second body is capable of accepting concrete cast into it. Construction composite panel according to claim 1, characterized in that the concrete layer covers at least a portion of the lower surface and covers at least a second end of an inlaid rafter. Composite building panel according to claim 1, characterized in that the first end extends above the upper surface. Composite building panel according to Claim 5, characterized in that the concrete layer covers at least a portion of the upper surface and covers at least a first end of an in-built rafter. Construction composite panel according to Claim 5, characterized in that a first layer of concrete covers at least a portion of the upper surface and covers at least a first end of an inlaid rafter and a second layer of copper concrete. at least a portion of the lower surface and at least a second end of an inlaid rafter. Composite building panel according to claim 5, characterized in that the concrete layer covers at least a portion of the lower surface and covers at least a second end of a recessed rafter and the finishing surface is attached to the surface. first end of the built-in rafter. Composite building panel according to claim 8, characterized in that the finishing surface is selected from the group consisting of wood, rigid plastic, wood panels, concrete panels, cement panels, plasterboard, plasterboard, particulate boards, rigid plastic panels, a metal batten and combinations thereof. Construction composite panel according to Claim 1, characterized in that it comprises a first transverse element extending from the first end of an inlaid rafter, embedded below the upper surface, making contact with or extending to the upper surface. above the upper surface. Composite construction panel according to claim 1, characterized in that it comprises a second transverse element extending from the second end of the in-built rafter. Composite construction panel according to claim 1, characterized in that the inlaid rafters comprise one or more utility holes located in the inlaid rafters between the lower surface of the central body and the second end of the inlaid rafters and the space. Defined by the lower surface of the central body and the second ends of the inlaid rafters is adapted to accommodate utility lines. Construction composite panel according to Claim 1, characterized in that the center body comprises a male end and a female end. Composite building panel according to claim 12, characterized in that the utility lines are one or more selected from the group consisting of hydraulic lines, waste lines, notches, telephone lines, cable TV lines. , antenna lines, power lines, ductwork and gas lines. Construction composite panel according to Claim 1, characterized in that the inlaid frame rafters extend longitudinally in the central body substantially along its entire length. Composite construction panel according to Claim 1, characterized in that the inlaid frame rafters comprise a material selected from the group consisting of metal, construction grade plastic, composite materials, ceramics and the like. Composite construction panel according to claim 16, characterized in that the inlaid frame rafters comprise a metal selected from the group consisting of aluminum, steel, stainless steel, tungsten, molybdenum, iron and alloys and combinations of such metals. Composite construction panel according to Claim 1, characterized in that the inlaid frame rafters have a form thickness of 0.4 to 10 mm. Composite construction panel according to claim 1, characterized in that it comprises two or more embedded rafters, wherein the distance between the embedded rafters is from 10 cm to 110 cm. A composite building panel according to claim 1, characterized in that the expanded polymer matrix comprises one or more polymers selected from the group consisting of vinyl aromatic monomer homopolymers; copolymers of at least one vinyl aromatic monomer with one or more divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile and / or maleic anhydride; polyolefins; polycarbonates; and their combinations. Construction composite panel according to Claim 13, characterized in that the male end of the central body comprises a tongue edge and the female end of the central body comprises a female notch edge which facilitates male and female union between one another. a first central body and a second central body to form one or more combined composite building panels, wherein the concrete layer is continuous on at least a portion of the combined upper and / or lower surfaces. Composite building panel according to claim 1, characterized in that the central body has a thickness measured as the distance between the first surface and the second surface of 2 cm to 50 cm. Construction composite panel according to Claim 1, characterized in that the central body comprises openings extending along the length of the central body. Composite construction panel according to claim 23, characterized in that the openings have a transverse sectional shape selected from the group consisting of round, oval, elliptical, square, rectangular, triangular, hexagonal and octagonal and the area cross section of 1 cm2 to 130 cm2. A composite construction panel according to claim 1, characterized in that the polymer matrix comprises an interpolymer of a polyolefin and in situ polymerized aromatic vinyl monomers. Composite building panel according to Claim 1, characterized in that the polymer matrix comprises carbon black, graphite or a combination thereof. Construction composite panel according to Claim 1, characterized in that the central body includes a beam I channel extending from the upper surface of the central body and opening thereon and positioned between a first embedded rafter. and a second built-in rafter. Construction composite panel according to Claim 1, characterized in that the first end extends above the upper surface, the concrete layer covers at least a portion of the upper surface, the first end and at least one channel of the upper surface. I beam is filled with concrete. Composite construction panel according to claim 28, characterized in that the concrete reinforcement bars are positioned in the beam channel I. Construction composite panel according to Claim 1, characterized in that the central body with at least one embedded structural rafter is continuously or semi-continuously molding an expanded plastic central body with two or more embedded rafters. partially embedded in it. Composite construction panel according to claim 1, characterized in that the T-slots are cut or molded on a central body surface. Construction composite panel according to Claim 4, characterized in that at least one second end of an in-built rafter is attached to a reinforcing wire mesh and the concrete layer coats the second end and the reinforcing mesh. reinforcing wire. A composite building panel according to claim 7, characterized in that at least one first end of an inlaid rafter is attached to a first reinforcing wire mesh, and the first concrete layer coats the first end and the first reinforcing wire mesh, and at least a second end of an inlaid rafter is attached to a second reinforcing wire mesh, and the second concrete layer coats the second end and the second reinforcing wire mesh. Composite construction panel according to Claim 1, characterized in that the concrete is lightweight concrete. Building, characterized in that it comprises one or more composite building panels according to claim 1. Method of constructing a building, characterized in that it comprises: mounting the composite building panel according to claim 1 on a generally flat surface and lifting a first end of the composite building panel while a second The end remains stationary, resulting in the orientation of the building panel to form a building wall. 37. Building, characterized in that it is constructed according to the method of claim 36. Building, characterized in that it comprises one or more composite paving panels according to claim 2. Building, characterized in that it comprises one or more insulated concrete forms according to claim 3.