PT101733B - PAINTERS TYPE SANDUICHE, PROCESS OF MANUFACTURE OF PAINTERS AND CONSTRUCTION SYSTEM USING PAINTERS. - Google Patents

Abstract

The object of the present invention is to provide construction panels 1, the process for manufacturing the panels and a construction system using the panels. The panels 1 form a strong casing, which is completely closed, inside which there is a nucleus of rigid foam 4, preferably made from expanded polyurethane, formed by two metallic sheets with the shape of a tray 2a, 2b, which are fitted together, an insulating strip 3 being interposed in the zone where the said trays fit together in order to guarantee thermal insulation between the said sheets, and the edges of the said casing 2 having a groove in the shape of a U 5, and the principal faces of the said panel being coated with composite coatings in accordance with the environment with which each one of them is in contact 21, 22, 23, 24, 25, 26. The process for manufacturing the said panels 1 comprises producing unworked (unfinished) rough outlines, by cutting metal sheets, the shaping of the said unworked rough outlines, trays 2a, 2b being obtained, the edges of which have the shape of a Z with perpendicular wings (tabs), treating against rust and cleaning the said trays 2a, 2b, fitting the said trays 2a, 2b together, with the interposition of a seal made from insulating material 3 in the zone where the said trays fit together so as to obtain a hollow unitary casing, the placing of the said unitary casing in a press and pressure-injection of the components of a product forming low-density rigid foam of high strength 4. The construction system of the invention comprises the production of buildings using the panels 1 in a strong structure in beams and/or in sections (profiles) extruded by traction in isophthalic polyester resin, in such a manner that the structural elements in contact with the outside environment are formed by thermally-insulating, non-oxidizing materials. The present invention is applicable, for example, in the civil-construction industry. <IMAGE>

Description

DESCRIPTIVE MEMORY

Sandwich panels, panel manufacturing process and construction system using the panels

This invention is in the field of the civil construction industry, and refers to self-supporting sandwich panels for construction, the manufacturing process of the panels and the construction system that uses said panels.

Conventionally, such panels comprise a core of insulating material sandwiched between two spaced sheets, the edges of the panel being closed by connection profiles, which are part of an assembly arrangement, which can be of the most varied types. Examples are the sandwich panels described in GB-A-1 072 595, EP 0 240 161, EP 0 324 282, EP 0 361 727, EP 0 542 501 and US420626.

The manufacture of sandwich panels with a rigid foam core is described, for example, in US 3 846 525 and EP 0 248 547, mainly referring to the composition of the foaming product, its preparation and its injection process. between two spaced plates.

The sandwich panels according to is sandwiched between flat bars whose core edges are less than 1 m, formed by extensions that make up an arrangement the inconvenience have thermals between the two faces in order to isolate between them being used problem

The panels described in patent EP 0 542 501 differ from those of the present invention, since the shape of the edges of the trays that form the panels does not provide mechanical strength comparable to those of the present invention, the tray fitting system being completely different, which requires the use of a profiled insulating joint with a special shape. The panels have no grooves in the midline of the

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contour, to accommodate in the sambladura its interior a tongue of tongue. The trays of the inventions are not slidable and

The panels described in the patent US4205267, which are structural panels, intended for use on roofs, their structural strength is not conferred by the shape of the edges of the metal trays that constitute them. In addition, the panels do not have grooves in the midline of their thickness and along the entire development of their contour, preferably in a U-shape, which allows them to accommodate inside a tongue of a tongue assembly arrangement.

In order to obtain a satisfactory level of thermal insulation, the choice of material for the connection profile is limited. This limitation of choice also has to do with the ability of the connection profile to transmit the forces exerted on the outer plate to the support structure on the inner side of the panel, since the known materials, which offer sufficient thermal insulation, do not offer sufficient mechanical resistance. This problem is further aggravated if mechanical resistance is required over a wide range of temperatures, as is the case with retardant or fire resistant panels. There is also an additional problem with the aforementioned panels, which is related to the fact that the connection profile is assembled prior to the formation of the core and is then not changed in particular, fixed in position by the foam core, it is possible to replace with a different type as long as the

Due to this, a connection profile or adapted to a sandwich application.

Thus, it is one of the objectives of the present invention to provide sandwich panels comprising an insulating material core, sandwiched between two preferences, rigid foam, metal sheets, whose edges are made up of bent extensions of said sheets, which gives the panel, thus structured, a great mechanical resistance to the different types of efforts (compression, flexion and

756 cut along the main axes). The panel is very light, which makes it easy to transport, handle, apply and store. The panel geometry is stable and has tight dimensional tolerances. It is completely closed, ensuring the insulation between its main faces, in the bending and fitting area by using an insulating strip, which allows a thermal cut, with a higher coefficient than the foam core.

The panels are rectangular, having two main faces and four contouring edges defined by the thickness and one of the two dimensions of the panel faces. They are mainly intended for the construction of walls. The edges of the panel have a groove in its midline of thickness and along the entire development of the contour, preferably in a U-shape, which allows it to accommodate inside a tongue of a tongue assembly arrangement, for the interconnection of the panel to another panel, structural element, base support, etc. .

The panels, according to the present invention, are coated on their two main outer faces, with composite coatings according to the environment with which each one is in contact.

The use of panels in accordance with the present invention allows for a significant reduction in surface finishes, since the clearances in the joints between the panels, after their assembly are small, and can therefore be gained only through coverings. simple, or by using: i) exteriors - thick paints, hydraulic bars, mixed bars (acrylic + hydraulic) and others;

ii) interiors - wallpapers on the covering panels, finishing coatings (for example: wood, cork, tiles, ceramics, stone, etc.).

The panel according to this invention also presents great versatility and architectural versatility, adapts to environments of multiple aggressiveness, according to the coatings used, great longevity, excellent response to earthquakes, due to the characteristics of mechanical resistance and total sealing, low density, absorption capacity of

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-4energy due to joint deformation.

Another object of the present invention is to provide a panel manufacturing process, which comprises.

- obtaining rough drafts, by cutting sheet metal treated against corrosion, with the appropriate dimensions,

- the bending of said rough sketches, in order to obtain trays, whose edges have, in cut, the shape of a projection / recess in Z of perpendicular flaps;

- the treatment against oxidation of said trays,

- the fitting of two of said trays, with the interposition of a joint element of insulating material in the area where they are fitted, in order to obtain a single-hollow, unitary and hollow type enclosure, with both trays being thermally insulated from each other ;

- placing said unitary casing in a press and injecting, under pressure, the components of a low-density, high-strength rigid foam forming product. To the main faces of the panels thus obtained, composite coatings are applied according to the environment with which each one is in contact.

It is yet another object of the present invention to provide a construction system that allows:

- fast construction, ·

- the use of few elements,

- little manpower;

- obtaining buildings that are completely thermally insulated from the outside, (without any elements in contact with the outside environment that are thermal conductors);

- good sound insulation; and

- high comfort from the point of view of preserving humidity.

In view of the resistant objective, which adjoins the walls preferably, by profiles, extruded synthetic composite fitting the panels through the above-mentioned dispositions, exterior, is through pillars and lintels by traction and reinforced by sandwich type of assembly the structure made , from the base with starting fibers, in a material which are mentioned above, by means of a tongue. The structure

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of the roof can also be made, and preferably, by means of pillars, beams, or profiles, extruded by traction from composite material reinforced by fibers, for reasons related to the combination of the following thermal coefficient insulation, f ac i1 age interior structure may be the economic motive in other materials, such as with pillars, beams or metal profiles. Said panels are connected to each other by a dovetail arrangement of the type: female fitting, built-in tongue, female fitting.

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According to the present invention, the construction system comprises the assembly of the pillars, panels and base support on a reinforced concrete platform, conveniently prepared on the implantation site, in order to obtain a solid and well-built building. isolated. The panels, which make up the building's exterior walls, are laid and connected to the base platform by the interposition of a beam and tongue extruded by traction from fiber-reinforced composite synthetic material. On the interior walls, the panels, according to the invention, are supported on the base platform with the interposition of a tongue attached to said base plate. Said panels are joined together by means of a tongue-type assembly arrangement, female fitting. The solidarity of said panels with the other construction elements, vertically and horizontally, is also done by fitting said U-slots with the tongues solidified in said construction elements, which can also be connected by other profiles and / or by other conventional ways. The panels can be cut to adapt to other measures, manually or by machine, and grooves can be cut in their cut edges, preferably in the shape of a U and added or not false edges, preferably in metal sheet of the same quality of that used in the rest of the panel, as well as the execution of openings, such as those for windows and doors, maintaining the guarantee of a thermal cut on the exterior walls.

According to the construction system of the invention, all water, gas, etc., as well as

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-6Thus, the solutions, electricity, or within the included, television, radio, telephone, structural or factory elements, within the

It should be noted that the inventions, problems have been conceived, which are placed on the wall panel constructions where, for example, walls, the introduction of movable or old walls.

resources aooi panels, in accordance with to respond to an area without Civil Construction, a set of solutions, for structural are conditioned,, the replacement of or removable, etc., the alteration of spaces either in crue if given to buildings follows, with the aid of the title of the example, no attached drawings, in which:

fig. 1 side view comprised of a preferred, limiting embodiment thereof, together with those shown a view from the front description, a top view and one of the panel according to the invention;

a schematic detail represents a schematic detail of a panel of the invention, coverings in the finish which are inside and fig. 3 shown on the outside of said panel is a diverse cut;

fig- 4 is a schematic section of fig. 3, but with a U-shaped tongue, fit U-shaped;

fig. 5 is two panels of a cut and schematic according to the invention;

one of a panel in the finish which is inside and the panel identical to the one inserted in the respective fig. 6 is a schematic horizontal section of a panel showing the dovetail arrangement of connecting said panel against a plane;

fig. 7 is a schematic section of an arrangement of

756 fitting an outer panel, cut, on a pillar, with the fitting edge worked topically at the foam core level;

fig. 8 is a schematic section of a fitting arrangement of an interior panel, cut, on a pillar, with the fitting edge worked to the top at the foam core level, · fig. 9 is a schematic section of an arrangement for fixing an interior panel, cut off, to a wall;

fig. 10 is a detail, in schematic section, of the connection of the outer panel to the base plate (lower lintel) according to the system of the invention;

fig. 11 is a schematic section of a connection arrangement of orthogonal exterior panels on a corner pillar;

The fig. 12 is a schematic cut of a header in wall exter ior (header lintel); The fig. 13 is a schematic section of the lintel connection in

header with structure and cover according to the system of the invention;

The fig. 14 is a cut schematic link of a panel t ¹ common rim and trim door; The fig. 15 represents a used window of according to system of the invention;

is a schematic rim cut along line A-A in fig. and the window frame, · fig.

structure shows, respectively, a roof plan view constructed according to the de system of the invention;

fig.

main and shows views, respectively, in plan, elevated right side elevation, of a house built of

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-8 according to the system of the invention.

panel 1, according to the invention, shown in fig. 1 and 2, is a fully sealed element, with a sheet metal enclosure 2, consisting of two sheet metal trays 2a and 2b fitted together, with the interposition of an insulating joint 3 in polyethylene tape, and an insulating core 4 in

foam

It includes, in each of its constitutes a female fitting 5, a dovetail arrangement preferably, the dimensions of 2.70 m (inner wall) or 2.60 m x outer wall).

rigid low-density expanded polyurethane, edges, a U-slot, intended to be part of one of which tongue and has, x 1.00 m x 0.08 m (panels

0.08 m (panels of

Panel 1, shown in fig. 2 (exterior wall panel), takes a painting based on vinylacrylic resin and is coated on its face in contact with the outside environment, with a layer of mortar (mortar) plus reinforcement 21, a layer of plaster (mortar) 22 and a finishing layer (waterproof textured paint) 23. Layer 21 is structured by a fiberglass reinforcement, with a 5mm square mesh, completely embedded in adhesive mortar, similar to the mortar that constitutes the plaster layer 22. A plaster layer 22 is a barrier layer, superimposed on said layer 21. The use <of these two symbiotic and structured layers, involving the entire exterior face of the construction, constitutes an excellent and stable protection of the panels against shock and erosion by atmospheric agents, eliminates any possibility of cracks and resists climatic variations. The two layers 21 and 22 form an insulating mantle, which does not require any maintenance, eliminates the problems of condensation, and constitutes an element of high value in relation to aspects of hygiene and healthiness of the construction. The finishing layer 23 is a quartz-pastic coating layer about 1 mm thick. It is a coating, durable, washable, resistant to shocks, weather and impervious to rainwater and steam.

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Ο panel 1, shown in fig. 2 (outer wall panel), is coated on its face in contact with the interior of the building, with a layer of mat 24, a plate 'rigid 25' and a layer of finishing paint 26. The layer of mat 24 consists of a layer of extruded low density polyethylene foam, about 5 mm thick and that adds acoustic insulation properties to said panel 1. Rigid plate 25 is a plasterboard on both sides, about 13 mm thick, which is applied over the layer of blanket 24 and is fixed to the metal plate of the panel by means of self-tapping screws or by means of rivets, which also serve as a means of fixing the layer of blanket 24. The layer of finishing paint 26 consists of an anti-fungal and bactericidal paint applied to said plate 25, and constitutes the decorative and protective finish of said plate 25.

As it is evident the coating of the faces of said panels 1, used in the interior partitions of the building, in addition to taking a base painting of vinylacrylic resin, they use coatings of the same type as indicated for the interior face of the exterior wall panel or they can even do not take any type of covering, depending on the type of room in which they are arranged.

The panels 1 can be cut and worked to the top at the level of the foam core, and may include pieces made of sheet metal, to protect the cut edges. Such pieces may be presented in the form of two solidified pieces, with the interposition of an insulating tape, the set having a shape identical to the previous tops of panels 1, or still other shapes that only protect said cut edges (see figs. 7 and 8).

Fig. 3 shows a panel 1 in section, showing the same type of coating shown in fig. 2.

In fig. 4 is shown a panel 1 with a U-shaped tongue 41 consisting of a profile extruded by resin traction

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-10 of isophthalic polyester, reinforced with glass fibers, fitted in the U 5 groove of said panel 1 and used in the assembly arrangement for the connection of the panels to other structural parts or plates.

In fig. 5 the U 51 double tongue assembly arrangement is shown for the connection of two panels 1 to each other, said tongue 51 consisting of two profiles extruded by traction of isophthalic polyester resin reinforced with glass fibers, connected together .

In fig. 6 shows an assembly arrangement for connecting panel 1, for example, to a plane by means of a tongue 41, integral with said plane.

In figs. 7, 8 are shown two types of panel connections 1, cut and worked to the topia, with the edges protected, respectively, with a piece 71, consisting of two half pieces, to prevent the thermal bridge (outer panel), and one one piece piece 81 (inner panel).

In fig. 9 is shown another type of connection of the inner panel cut without tongue.

The manufacturing process for panels 1 of the invention comprises:

- the cutting of galvanized or lacquered sheets, raw, to obtain drafts;

- the bending of the sketches, obtaining two trays, whose edges have the shape of Z, with perpendicular flaps;

- the treatment against the oxidation of said trays, which consists, after bending, in the cleaning and removal of impurities and grease, by means of a primary apparatus, consisting of two components based on vinyl butyral resin, which provides, in addition to perfect cleaning, good adhesion inside the polyurethane foam and outside the coverings;

- the fitting of the two trays with the interposition of a

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insulating joint, of extruded polyethylene, in the area where the trays fit (free flaps on the respective edges), in order to obtain a hollow unitary casing, the two 'trays being thermally insulated from each other, with displacements between trays being prevented, already in this phase by means of fixation by metallic elements (rivets or screws);

- the formation of a core in low density expanded polyurethane foam, in an injection line, said unitary casing being placed in a press, where the injection of the components of a low polyurethane rigid foam forming product is performed density and high resistance, which adheres perfectly to the internal walls of said enclosure; and

- the coating of its two main faces, with a painting based on vinylacrylic resin, in addition to the composite coatings according to the environment with which each one will be in contact.

According to the construction system of the invention, the resistant structure of the exterior walls of the building is made by means of pillars, or profiles, extruded by traction of isophthalic polyester resin, reinforced by glass fibers, in which the type panels will fit. aforementioned sandwiches (see figs. 4, 5, 6, 7, 8, 10, 11, 12, 13), by means of a dovetail arrangement, the roof structure also being made by means of beams, or profiles, extruded by traction of isophthalic polyester resin reinforced by glass fibers. The interior structure, that is, the interior walls, will preferably be made by means of pillars and beams, or profiles, metallic, for economic reasons. Other materials may also be used, such as wood, etc. Panels 1 are connected together by the dovetail arrangement shown in fig. 5 (female insert 5, built-in tongue 51 and female insert 5), where tongue 51 is preferably a double profile extruded by traction of isophthalic polyester resin reinforced with glass fibers.

According to the present invention the construction system

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-12 understand, as seen in the detail of fig. 10, the assembly of panels 1 on a base plate or reinforced concrete base 101, conveniently prepared on the T implantation site, by means of the U beam 102, extruded by traction of isophthalic polyester resin, reinforced by fibers, solidified in the said base plate 101, to which is attached a U-shaped tongue 41, extruded by traction of isophthalic polyester resin reinforced by fibers, which will fit into the female fitting 5, of said panel 1. In fig. 10 there is also shown a protective ruler 103 of insulating material, a footer support ruler 104, in which the footer 105 and the floor covering 106 will be attached. When panels 1 are used on the interior walls, they are based on the base plate with the interposition of a tongue 41 attached to said base plate, in the same way as shown in fig. 6. Panels 1 are attached to the other building elements, vertically and horizontally, also by fitting said U-slots in tongues 41, constituted by U-profiles, solidified in said building elements (see figs. 4, 5, 6, 7, 8, 10, 11), as well as can be connected in any other conventional ways (see fig. 9).

In fig. 11 is shown, in detail and in section, the connection of two panels 1 to one of the corner pillars 72 and 111 extruded by traction of isophthalic polyester resin reinforced with glass fiber.

In fig. 12 is shown, in detail and in section, a header lintel of a panel 1, consisting of a U-profile 121 extruded by traction of isophthalic polyester resin reinforced with glass fibers, fitted on top of said panel 1 and attached to the panel 1 by conventional fastening means.

In fig. 13 is shown, in detail and in section, the connection of the header lintel to the roof structure. This figure shows a part of the plasterboard false ceiling 131, on which an insulation can be installed, for example, in a rock wool blanket, not

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-13represented;

- a series of ceiling beams 132, on which a floor can be installed;

- U-beams 133 of the roof structure;

- L 134 beams supporting beam 133;

- I 135 beams, supported on beams 133;

- sub-tile plates 136, finishing plates 137, U-beam with composite flaps 138; and

- finishing strips 139.

Preferably, beams 133, 134, 135 are traction-extruded beams in isophthalic polyester resin reinforced with glass fibers. However, beams that are part of the roof structure, but that are not in contact with the outside environment, for example, beams 132 and 138 can be made of other materials such as metal, wood, composites, etc. .

In fig. 14 is shown a panel 1, intended for interior walls, having fixed the frame and the door fittings in wood 141.

In figs. 15 and 16 there is shown a window usable in the building according to the invention, the trim ring 153 of which is made of profiles extruded by traction in resin reinforced with glass fibers. Frames 151, 152 are conventional.

According to the construction system of the invention, and as seen in fig. 10 dashed plumbing 107 of water, gas, etc. , as well as the wiring for electricity, television, radio, telephone, etc., pass together or inside the structural or support elements 102, and passages for them can also be included inside the panels or, possibly, be implanted from any other conventional way.

Claims (6)

1 - Sandwich panel, comprising a core of insulating material, preferably of rigid synthetic foam, of low density, sandwiched between two metal sheets, which form a resistant, completely closed, self-supporting enclosure, characterized by each of the tips metal plates have the shape of a tray whose edges are cut in the shape of Z of perpendicular flaps, and said trays are fitted together, so as to form said closed envelope of said sandwich panel, by being interposed, in the fitting area (free edges of the edges) of said trays, a tape of insulating material, in order to guarantee the thermal insulation between said two trays, for each of the edges of said panel has a U-shaped groove in the its middle part and along its length and because the main faces of said panel are coated with composite coatings, for example, thick paints, hydraulic busbars, b mixed wires (acrylic + hydraulic), according to the environment with which each one is in contact. Construction panel according to claim 1, characterized in that said low density rigid foam is polyurethane foam, being totally isolated from the outside environment, and said insulating tape is an extruded polyethylene tape, and in that said insulating tape provide at least twice as much insulation as said polyurethane foam. Process for manufacturing the panels according to claim 1 or 2, characterized by comprising: - obtaining rough drafts by cutting metal sheets to the appropriate dimensions and treating them against corrosion, - the bending of said rough sketches, in order to obtain trays, whose edges have, in the shape of a Z, perpendicular flaps, Ί & 756 'Ί r-2/3 - - ο treatment against oxidation and cleaning of said trays, - the fitting of two of said trays, - the interposition of a joint of insulating material in the fitting area of said trays, in order to obtain a hollow unitary casing, said two trays being thermally insulated from each other, - placing said unitary casing in a press and injection under pressure of the components of a low-density, high-strength rigid foam forming product within said unitary casing. Process according to claim 3, characterized in that the main faces of said panels are coated with composite coatings according to the environment with which each one is in contact. Construction panel according to claim 3 or 4, characterized in that said low density rigid foam is polyurethane foam and said insulating tape is an extruded polyethylene tape, and in that said insulating tape provides at least insulation , twice as high as that of said polyurethane foam. Construction system using the panels of claim 1 or 2, characterized in that the structure of the outer walls is preferably made by means of pillars or profiles, extruded by traction from a composite synthetic material reinforced by fibers, in the the said sandwich panels are to be joined together, by means of a dovetail arrangement, the structure of the roof also preferably being made by means of beams, or profiles, extruded by traction from fiber-reinforced composite synthetic material, and the interior structure, the floor support beams and the roof structure being carried out, preferably by means of beams, or profiles, for example, metallic, and because said panels are connected together by an assembly arrangement (fitting female, false tongue, 76 756 A system according to claim 6, characterized in that said resin is an isophthalic polyester resin and said fibers are glass fibers. System characterized by a machine, that is, r at its edges the U-shape is preferably made of sheet metal of the same or false inserts as that used in the rest of the panel and the same shape as the edges with the same uncut insulator System according to 6 or call the claim characterized by all the water, gas pipelines, such as electricity, television, radio, etc., pass together or inside the structural or support elements, or include passages for them inside the said panels.