WO2024251336A1 - Procédé de fabrication d'un élément de construction de bâtiment et élément de construction de bâtiment - Google Patents
Procédé de fabrication d'un élément de construction de bâtiment et élément de construction de bâtiment Download PDFInfo
- Publication number
- WO2024251336A1 WO2024251336A1 PCT/DK2024/050135 DK2024050135W WO2024251336A1 WO 2024251336 A1 WO2024251336 A1 WO 2024251336A1 DK 2024050135 W DK2024050135 W DK 2024050135W WO 2024251336 A1 WO2024251336 A1 WO 2024251336A1
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- WO
- WIPO (PCT)
- Prior art keywords
- building construction
- construction element
- wall structure
- foam
- structures
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures
Definitions
- the present invention relates to a building construction element com- prising a sandwich structure comprising: - one or more first outer plates forming a first wall structure of the building construction element, wherein the area between any adja- cent first outer plates constitutes a joint; - one or more second outer plates forming a second wall structure of the building construction element, wherein the area between any adjacent second outer plates constitutes a joint; - optionally a number of flange members or joint cover plates extend- ing along and covering the inside portion of the joints and - a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of the first wall structure and a second flange member extend- ing along and covering the inside portion of the second wall struc- ture or b) the first wall structure and the second wall structure.
- the present invention also relates to a method for manufacturing such building construction element.
- Prior art It is known to manufacture construction elements such as walls, floor elements, and horizontal divisions formed as sandwich structures com- prising polyurethane (PUR) or polyisocyanurate (PIR).
- sandwich structures com- prising polyurethane (PUR) or polyisocyanurate (PIR).
- PUR polyurethane
- PIR polyisocyanurate
- sandwich structures are typi- cally produced by using a large block of foam, the block is cut into piec- es of desired thicknesses.
- intermedi- ate structures made of wood are typically used.
- a building construction element is typically constructed in such a manner that the intermediate structures have sufficiently strength to ensure that the overall strength of the building construction element fulfils prescribed requirements.
- the foam contributes to the overall strength of a building construction element, this is not taken into consideration in the prior art. Accordingly, the dimensions of the intermediate structures are typi- cally larger than required. Accordingly, it would be advantageous to provide a method that reduc- es or even eliminates the above-mentioned disadvantages of the prior art. It is an object of the present invention to provide a method, by which it is possible to reduce the dimensions of the intermediate structures and at the same time ensure that the overall strength of the building con- struction element fulfils the prescribed requirements. Summary of the invention The object of the present invention can be achieved by a method as defined in claim 1 and by a building construction element as defined in claim 13 and a building as defined in claim 14.
- the method is a method for manufacturing a building construction ele- ment, the method comprising: - forming a first wall structure of the building construction element from one or more (e.g. a plurality of) first outer plates, wherein the area between adjacent first outer plates (if any) constitutes a joint; - forming a second wall structure of the building construction element from one or more (e.g.
- first flange member extending along and covering the inside por- tion of (e.g. a first joint of) the first wall structure and a second flange member extending along and covering the inside portion of (e.g.
- PUR polyurethane
- PIR polyisocyanurate
- the intermediate structures are made of new PUR and/or PIR.
- the intermediate structures are made of PUR and/or PIR comprising fibres (e.g. glass fibres, carbon fibres or ar- amid fibres).
- the intermediate structures are made of PUR and/or PIR comprising recircled PUR and/or PIR material.
- fibres e.g.
- the method is a method for manufacturing a building construction ele- ment.
- the building construction element is a wall.
- the building construction element is a horizontal division.
- the building construction element is a floor element. The method comprising: - forming a first wall structure of the building construction element from one or more (e.g. a plurality of) first outer plates, wherein the area between adjacent first outer plates (if any) constitutes a joint.
- the method comprising: - forming a first wall structure of the building construction element from a single first outer plate. In an embodiment, the method comprising: - forming a first wall structure of the building construction element from a plurality of first outer plates, wherein the area between adja- cent first outer plates constitutes a joint. The method comprising: - forming a second wall structure of the building construction element from one or more (e.g. a plurality of) second outer plates, wherein the area between adjacent second outer plates (if any) constitutes a joint. In an embodiment, the method comprising: - forming a second wall structure of the building construction element from a single second outer plate.
- the method comprising: - forming a second wall structure of the building construction element from a plurality of second outer plates, wherein the area between adjacent second outer plates constitutes a joint.
- the method comprising: - arranging a number of flange members or joint cover plates along the inside portion of the joints or the first wall structure.
- the method comprising: - arranging a number of flange members along the inside portion of the joints or the second wall structure.
- the method comprising: - arranging a number of joint cover plates along the inside portion of the joints or the first wall structure.
- the method comprising: - arranging a number of joint cover plates along the inside portion of the joints or the second wall structure.
- the method comprising: - arranging a plurality of spaced apart intermediate structures to ex- tend between: a) a first flange member extending along and covering the inside por- tion of the first wall structure and; b) a second flange member extending along and covering the inside portion of the second wall structure, - filling PUR foam or PIR foam into the space between the first wall structure and the second wall structure.
- the method comprising: - arranging a plurality of spaced apart intermediate structures to ex- tend between: - the first wall structure and the second wall structure, - filling PUR foam or PIR foam into the space between the first wall structure and the second wall structure.
- the method comprising: - arranging a plurality of spaced apart intermediate structures to ex- tend between: a) a first flange member extending along and covering the inside por- tion of a first joint the first wall structure and; b) a second flange member extending along and covering the inside portion of a second joint the second wall structure, - filling PUR foam or PIR foam into the space between the first wall structure and the second wall structure.
- the method comprising: - determining the load bearing capacity of the PUR foam or PIR foam filled into the space between the first wall structure and the second wall structure.
- the load bearing capacity of the PUR foam or PIR foam filled into the space between the first wall structure and the sec- ond wall structure is determined by: a) detecting the density of the PUR foam or PIR foam filled into the space between the first wall structure and the second wall structure and b) using one or more predefined mechanical values related to the PUR foam or PIR foam.
- said predefined mechanical values are the maximum load-carrying capacity.
- the maximum load-carrying capacity is at least 3000 kg/m 2 .
- the maximum load-carrying capacity is at least 4000 kg/m 2 .
- the maximum load-carrying capacity is at least 5000 kg/m 2 .
- the density of the PUR or PIR can be selected in order to achieve a predefined the maximum load-carrying capacity (e.g. 5000 kg/m 2 ).
- the density of the PUR or PIR is in the range 20-80 kg/m 3 .
- the density of the PUR or PIR is in the range 30-70 kg/m 3 .
- the density of the PUR or PIR is in the range 40-60 kg/m 3 .
- the density of the PUR or PIR is in the range 45-55 kg/m 3 .
- the method comprising: - determining the required load bearing capacity of the intermediate structures of the building construction element in order to fulfil one or more predefined requirements related to the load bearing capaci- ty of the building construction element.
- the required load bearing capacity of the intermedi- ate structures of the building construction element in order to fulfil one or more predefined requirements related to the load bearing capacity of the building construction element may be determined by performing a pre-test of the intermediate structures or the wind turbine, from which the intermediate structures are taken.
- the required load bearing capacity of the intermedi- ate structures of the building construction element in order to fulfil one or more predefined requirements related to the load bearing capacity of the building construction element may be determined by using prede- fined values and measuring the thickness of the intermediate struc- tures.
- a predefined requirement related to the load bear- ing capacity of the building construction element is the required min- imum load bearing capacity of the building construction element. In an embodiment, a predefined requirement related to the load bear- ing capacity of the building construction element is the required min- imum compressive strength of the building construction element. In an embodiment, the minimum compressive strength of the building construction element is 10 MPa. In an embodiment, the minimum compressive strength of the building construction element is 15 MPa. In an embodiment, the minimum compressive strength of the building construction element is 20 MPa.
- the method comprising: - selecting the dimension of the intermediate structures of the build- ing construction element in dependency of the determined required load bearing capacity of the intermediate structures.
- the width of the intermediate structures of the building construction element is determined in dependency of the de- termined required load bearing capacity of the intermediate structures.
- the method comprising: - prior to construction of the building construction element conducting a mechanical test of the wind turbine blade and/or the suitable intermedi- ate structures to be used in the building construction element.
- the method comprising: - determining the force with which the PUR foam or PIR foam filled into the space between the first wall structure and the second wall structure exerts toward the intermediate structures placed adjacent to the PUR foam or PIR foam when an external force is exerted towards the intermediate structures along the length of the intermediate structures.
- the method comprising: - determining the maximum allowable distance between the inter- mediate structures to fulfil the one or more predefined require- ments in dependency of the determined required load bearing capacity of the intermediate structures.
- each intermediate structure is a continuous section from a wind turbine blade.
- the method comprising: - prior to construction of the building construction element defining a plurality of different types of construction elements having different predefined minimum required load capacity; - determining the thickness of a group of suitable intermediate struc- tures to be used in the building construction element and - selecting among said types of construction elements one single type having a load capacity above its predefined minimum required load ca- pacity when the suitable intermediate structures are used in the build- ing construction element.
- determining the thickness of the intermediate struc- ture corresponds to determining the load capacity of the intermediate structure.
- the blade has different thicknesses. The idea is to use thicker parts for roof and floor separation and thinner for wall construction.
- the first wall structure extends parallel to the sec- ond wall structure.
- the intermediate structure extends perpendicular to the first wall structure and to the second wall structure.
- the flange members are made of a fire-resistant material.
- the flange members are made of concrete.
- the flange members are made of plaster.
- the intermediate structure is at least partly covered by a fire-resistant material. In an embodiment, the intermediate structure is fully covered by a fire- resistant material.
- the method comprising: - gluing each intermediate structure to the flange members or wall structures between which the intermediate structure extends. In an embodiment, the method comprising: - removing the wall structures; - grinding the intermediate structure and PUR or PIR of the build- ing construction element into smaller pieces of the building con- struction element; - molding a new element by using the smaller pieces of the build- ing construction element.
- the new element is a pillar or column.
- the new element is manufactured by adding a suita- ble type of resin e.g. a polyurethane resin comprising copolymers made up of polyol and isocyanate components.
- the resin is a polyurethane resin.
- the building construction element according to the invention is a build- ing construction element manufactured by using a method according to the invention.
- the building construction element comprising a sandwich structure comprising: - one or more first outer plates forming a first wall structure of the building construction element, wherein the area (if any) between adjacent first outer plates constitutes a joint; - one or more second outer plates forming a second wall structure of the building construction element, wherein the area (if any) be- tween adjacent second outer plates constitutes a joint; - optionally a number of flange members extending along and cover- ing the inside portion of the joints and - a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of the first wall structure and a second flange member extend- ing along and covering the inside portion of the second wall struc- ture or b) the first wall structure and the second wall structure, wherein each intermediate structure is a continuous section from a
- the sandwich structure comprising: - a plurality of first outer plates forming a first wall structure of the building construction element, wherein the area between adjacent first outer plates constitutes a joint; - a plurality of second outer plates forming a second wall structure of the building construction element, wherein the area between adja- cent second outer plates constitutes a joint.
- outer plates are planar plates. A planar outer plate is lying in a single plane.
- a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of a first joint the first wall structure and; b) a second flange member extending along and covering the inside portion of the second wall structure.
- a plurality of spaced apart intermediate structures each extending between the first wall structure and the second wall structure. In an embodiment, a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of the first wall structure and; b) a second flange member extending along and covering the inside portion of a second joint the second wall structure. In an embodiment, a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of a first joint the first wall structure and; b) a second flange member extending along and covering the inside portion of a second joint the second wall structure.
- a joint cover plate extends along and cov- ering the inside portion of one or more first joints the first wall structure. In an embodiment, a joint cover plate extends along and cov- ering the inside portion of one or more first joint the second wall structure. In an embodiment, the first wall structure extends parallel to the sec- ond wall structure.
- the flange members are made of a fire-resistant material. In an embodiment, the flange members are made of concrete. In an embodiment, the flange members are made of plaster.
- the intermediate structure is at least partly covered by a fire-resistant material. In an embodiment, the intermediate structure is fully covered by a fire- resistant material.
- each intermediate structure extends perpendicular to the first wall structure and to the second wall structure.
- each intermediate structure is glued to the flange members or wall structures between which the intermediate structure extends.
- the glue is a PUR adhesive.
- the glue is a PIR adhesive.
- the glue is a PUR hot melt adhesive.
- the glue is an is inflammable, one-component ad- hesive.
- the glue is an is inflammable, two-component ad- hesive.
- each intermediate structure is mechanically at- tached to the flange members or wall structures between which the in- termediate structure extends.
- the mechanical attachment may be car- ried out by using various attachment types including one or more nails and/or one or more screws and/or one or more wedges.
- polyurethane (PUR) foam or polyisocyanurate (PIR) foam is filled into the space between the first wall structure and the second wall structure.
- the building construction element is a wall or a hori- zontal division.
- the building according to the invention is a building comprising a build- ing construction element according to the invention.
- the sandwich structure comprising: - a plurality of first outer plates forming a first wall structure of the building construction element, wherein the area between adjacent first outer plates constitutes a joint; - a plurality of second outer plates forming a second wall structure of the building construction element, wherein the area between adja- cent second outer plates constitutes a joint.
- a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of a first joint the first wall structure and; b) a second flange member extending along and covering the inside portion of the second wall structure.
- a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of the first wall structure and; b) a second flange member extending along and covering the inside portion of a second joint the second wall structure.
- a plurality of spaced apart intermediate structures each extending between: a) a first flange member extending along and covering the inside por- tion of (e.g. a first joint of) the first wall structure and; b) a second flange member extending along and covering the inside portion of (e.g. a second joint of) the second wall structure.
- a plurality of spaced apart intermediate structures each extending between the first wall structure and the second wall structure.
- a joint cover plate extends along and covering the inside portion of one or more first joints the first wall structure.
- a joint cover plate extends along and covering the inside portion of one or more first joint the second wall structure.
- the first wall structure extends parallel to the sec- ond wall structure.
- the flange members are made of a fire-resistant material.
- the flange members are made of concrete.
- the flange members are made of plaster.
- the intermediate structure is at least partly covered by a fire-resistant material. Hereby, it is possible to approve a fire rated building construction element.
- the intermediate structure is fully covered by a fire- resistant material.
- each intermediate structure extends perpendicular to the first wall structure and to the second wall structure.
- each intermediate structure is glued to the flange members between which the intermediate structure extends.
- PUR foam or PIR foam is filled into the space be- tween the first wall structure and the second wall structure.
- PUR foam or PIR foam is filled into the space be- tween adjacent intermediate structures.
- the building according to the invention is a building comprising a build- ing construction element according to the invention.
- the method comprising using a number of intermediate structures, wherein each intermediate structure is a continuous section from a wind turbine blade.
- each intermediate structure is a continuous section from a wind turbine blade.
- the method comprising: - prior to construction of the building construction element defining a plurality of different types of construction elements having different predefined minimum required load capacity; - determining the thickness of a group of suitable intermediate struc- tures to be used in the building construction element and - selecting among said types of construction elements one single type having a load capacity above its predefined minimum required load ca- pacity when the suitable intermediate structures are used in the build- ing construction element.
- determining the thickness of the intermediate struc- ture corresponds to determining the load capacity of the intermediate structure.
- the blade has different thicknesses.
- the thicker parts are used for roof and floor separation.
- the thinner parts of the wind turbine blades are used for wall construction.
- the method comprising: - prior to construction of the building construction element conducting a mechanical test of the wind turbine blade and/or the suitable intermedi- ate structures to be used in the building construction element.
- the first wall structure extends parallel to the sec- ond wall structure.
- the intermediate structure extends perpendicular to the first wall structure and to the second wall structure.
- the flange members are made of a fire-resistant material.
- the flange members comprise concrete. In an embodiment, the flange members are made of concrete. In an embodiment, the flange members comprise plaster. In an embodiment, the flange members are made of plaster. In an embodiment, the intermediate structure is at least partly covered by a fire-resistant material. In an embodiment, the intermediate structure is fully covered by a fire- resistant material. In an embodiment, the method comprising: - gluing each intermediate structure to the flange members between which the intermediate structure extends.
- FIG. 1A shows a perspective view of a building construction element according to the invention
- Fig. 1B shows another view of the building construction element shown in Fig. 1A
- Fig. 2A shows a perspective view of a building construction element according to the invention
- Fig. 2B shows another view of the building construction element shown in Fig. 2A
- Fig. 3A shows a perspective view of a building construction element according to the invention
- Fig. 3B shows a close-up view of at portion a building construction element according to the invention
- Fig. 4A shows a cross-sectional view of a building construction ele- ment according to the invention
- Fig. 4B shows a cross-sectional view of a building construction ele- ment arranged in a mold
- FIG. 4C shows a cross-sectional view of a building construction ele- ment arranged in a mold in a configuration in which PUR has been filled into the space between the first wall structure and the second wall structure of the building construction element;
- Fig. 5A shows how an intermediate structure is made of a continu- ous section from a wind turbine blade;
- Fig. 5B shows another view of how an intermediate structure is made of a continuous section from a wind turbine blade;
- Fig. 6A shows a prior art building construction element;
- Fig. 6B shows a building construction element according to the in- vention;
- Fig 6C shows a flow chart illustrating steps of a method according to the invention;
- FIG. 7A shows internal and external forces exerted to structures of a building construction element according to the invention
- Fig. 7B shows internal and external forces exerted to structures of another building construction element according to the in- vention
- Fig. 8A shows a cross-sectional view of a building construction ele- ment according to the invention
- Fig. 8B shows a schematic perspective top view of the building con- struction element shown in Fig. 8A
- Fig. 8C shows another view of a building construction element ac- cording to the invention
- Fig. 9A shows a cross-sectional view of a building construction ele- ment according to the invention
- Fig. 9B shows a schematic view of the building construction element shown in Fig. 9A
- Fig. 9A shows internal and external forces exerted to structures of a building construction element according to the invention
- Fig. 7B shows internal and external forces exerted to structures of another building construction element according to the in- vention
- Fig. 8A shows
- FIG. 10A shows a cross-sectional view of two building construction elements according to the invention
- Fig. 10B shows a cross-sectional view of the building construction elements shown in Fig. 10A in an assembled configuration
- Fig. 10C shows a perspective of a floor comprising a plurality of building construction elements according to the invention.
- the building construction element 2 com- prises a sandwich structure comprising: a) a plurality of first outer plates 4, 4’, 4’’ forming a first wall structure 14 of the building construction element 2 and b) a plurality of second outer plates 6, 6’, 6’’ forming a second wall structure 16 of the building construction element 2.
- Each area between adjacent first outer plates 4, 4’, 4’’ constitutes a joint 12.
- each area between adjacent second outer plates 4, 4’, 4’’ constitutes a joint 12.
- the first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of a fire resistant material.
- first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of a material that contains concrete. In an embodiment, the first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of concrete. In an embodiment, the first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of a material that contains plaster. In an embodiment, the first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of plaster. In an embodiment, the first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’’ are made of a material that contains bricks.
- first outer plates 4, 4’, 4’’ and/or the second outer plates 6, 6’, 6’’ are made of bricks.
- the sandwich structure comprises: a) a number of flange members 10, 10’ extending along and covering the inside portion of the joints 12 of the first wall structure 14 and b) a number of flange members 10, 10’ extending along and covering the inside portion of the joints 12 of the second wall structure 16.
- the sandwich structure further comprises a plurality of spaced apart intermediate structures 8 each extending between: - a first flange member 10 extending along and covering the inside portion of a first joint 12 the first wall structure 14 and - a second flange member 10’ extending along and covering the inside portion of a second joint 12 the second wall structure 16.
- Each intermediate structure 8 is a continuous section from a wind tur- bine blade as shown in and explained with reference to Fig. 5A and Fig. 5B.
- the first wall structure 14 and the second wall structure 16 extend par- allel to each other.
- Each intermediate structure 8 extends perpendicu- lar to the first wall structure 14 and the second wall structure 16.
- the first flange members 10 bear against and extends parallel to the first wall structure 14.
- the second flange members 10’ bear against and extends parallel to the second wall structure 16.
- each intermediate structure 8 is attached to a first flange member 10 and a second flange member 10’. Accordingly, each intermediate structure 8 and extends between a first flange member 10 and a second flange member 10’.
- each intermediate structure 8 is attached to a first flange member 10 and a second flange member 10’ by means of glue 24.
- a first flange member 10 and a second flange mem- ber 10’ extends between the first wall structure 14 and second wall structure 16 without covering any joint 12, 12’.
- Fig. 1B illustrates another view of the building construction element 2 shown in Fig. 1A. The space between the first wall structure 14 and second wall structure 16 has been filed with a polyurethane (PUR) foam 18 or polyisocyanurate (PIR) foam 18.
- PUR foam or PIR foam 18 supports the intermediate structure 8 and hereby prevents the interme- diate structure 8 from bending.
- the PUR foam or PIR foam 18 When the PUR foam or PIR foam 18 is filled (injected) into the space provides a between the first wall struc- ture 14 and second wall structure 16, the PUR foam or PIR foam 18 will exert a pressure towards the intermediate structure 8 from both sides of the intermediate structure 8. Accordingly, the intermediate structure 8 will be held in place by the PUR foam or PIR foam 18. When the PUR foam or PIR foam 18 has cured, a firm stabilizing support structure is build-up against the intermediate structure 8. The PUR foam or PIR foam 18 have very good properties concerning insulation. Accordingly, these types of insulation are suitable for being used in the construction industry.
- the low lambda value of PUR (less than 0.028 W/m . K o ) means that large amounts of energy can be saved when using PUR.
- Fig. 1B only illustrates a portion of a building construction element 2 according to the invention. In an embodiment, all spaces be- tween the first wall structure 14 and second wall structure 16 has been filed with PUR or PIR foam 18.
- Fig. 2A illustrates a perspective view of a building construction element 2 according to the invention. The building construction element 2 basi- cally corresponds to the one shown in and explained with reference to Fig. 1A. Several surfaces of the intermediate structure 8, however is covered by a fire-resistant material 28.
- the fire-resistant material 28 is plate-formed ad fits a surface of the intermedi- ate structure 8.
- the fire-resistant material 28 is made of a material that contains concrete.
- the fire-resistant material 28 is made of concrete.
- the fire-resistant material 28 is made of a material that contains plaster.
- the fire-resistant material 28 is made of plaster.
- the fire-resistant material 28 is made of a material that contains bricks.
- the fire-resistant material 28 is made of bricks.
- all surfaces of the intermediate structure 8 that are not covered by flange members 10, 10’ is covered by a fire-resistant material 28.
- FIG. 2B illustrates another view of the building construction element shown in Fig. 2A.
- the space between the first wall structure 14 and second wall structure 16 has been filed with PUR or PIR foam 18.
- the PUR foam or PIR foam 18 supports the intermediate structure 8 and hereby prevents the intermediate structure 8 from bending.
- the PUR foam or PIR foam 18 is filled (injected) into the space provides be- tween the first wall structure 14 and second wall structure 16, the PUR foam or PIR foam 18 will exert a pressure towards the intermediate structure 8 from both sides of the intermediate structure 8. Accordingly, the intermediate structure 8 will be held in place by the PUR foam or PIR foam 18.
- FIG. 3A illustrates a perspective view of a building construction element 2 according to the invention.
- the building construction element 2 basi- cally corresponds to the on shown in and explained with reference to Fig. 1A.
- the first outer plates 4, 4’, 4’’ forming part of the first wall structure 14 of the building construction element 2 have a different shape (width) than the one shown in and explained with refer- ence to Fig. 1A).
- a joint cover plate 30 covers the inside portion of the joint between the first outer plates 4, 4’ and that a joint cover plate 30 covers the inside portion of the joint between the first outer plates 4’, 4’’.
- none of the joints 12 in the first wall structure 14 are covered by a flange member.
- the joints 12 in the first wall structure 14 are covered by a joint cover plate 30.
- Fig. 3B illustrates a close-up view of at portion a building construction element 2 according to the invention.
- the building construction element 2 comprises a second wall structure 16 comprises two adjacent first outer plates 6, 6’ arranged bearing against each other along a joint 12.
- the building construction element 2 comprises a first wall structure 14 comprises two adjacent first outer plates 4, 4’ arranged bearing against each other along a joint.
- Several surfaces of the intermediate structure 8 extends between flange members 10, 10’ bearing against the inside surface of the first wall structure 14 and the second wall structure 16, respectfully.
- PUR foam or PIR foam 18 has been filled into the space provided be- tween the first wall structure 14 and second wall structure 16.
- the width D 1 of the intermediate structure 8 is smaller than the distance D 2 between adjacent intermediate structures 8.
- the width of the flanges 10, 10’ is larger than the width D 1 of the intermediate structures 8.
- Fig. 4A illustrates a cross-sectional view of a building construction ele- ment 2 according to the invention.
- the building construction element 2 comprises a sandwich structure comprising: a) a first outer plate 4 forming a first wall structure of the building con- struction element 2 and b) a second outer plate 6 forming a second wall structure of the building construction element 2.
- the first wall structure of the building construction element 2 may comprise several first outer plates 4.
- the second wall structure of the building construction ele- ment 2 may comprise several second outer plates 6.
- the one or more first outer plates 4 and/or the one or more second outer plates 6 are made of a fire resistant material.
- the fire resistant material may contain concrete or be made of concrete, contain plaster or be made of plaster.
- FIG. 4B illustrates a cross-sectional view of the building construction el- ement 2 shown in Fig. 4A arranged in a mold 32.
- the mold 32 comprises a top member 38 extending parallel to a bottom member 38’.
- the mold 32 comprises two spaced apart end press members 36 that are moveably arranged so that the distance between the end press members 36 can be changed in order to make the mold 32 fit the length of the building construction element 2.
- Each of the end press members 36 are connected to a connection member 34 that is attached to an actuator 32.
- An actuator 32 is ar- ranged and configured to displace a connection member 34 and the end portion 36 along a longitudinal axis of the mold 32.
- Fig. 4C illustrates a cross-sectional view of the building construction el- ement 2 arranged in the mold 32 shown in and explained with reference to Fig. 4B, in a configuration in which PUR or PIR 18 has been filled into the spaces between the first wall structure and the second wall struc- ture of building construction element 2.
- Fig. 5A illustrates how an intermediate structure 8 is made of a continu- ous section from a wind turbine blade 20 of a wind turbine 22.
- the wind turbine 22 comprises several blades 20 that eventually needs to be re- placed.
- FIG. 5B illustrates another view of how an intermediate structure 8 is made of a continuous section from a wind turbine blade 20.
- the wind turbine blade 20 is cut into several sec- tions 26, 26’. When this is done, a number of intermediate structures 8 are cut from each of the sections 26, 26’.
- intermediate structures 8 made of a continuous section from a wind turbine blade 20, it is possible to achieve a strong and reli- able building support structure and thus to provide a strong and reliable building construction element 2.
- the term “cut” should be interpreted as any suitable process, by which a number of intermediate structures 8 can be provided from each of the sections 26, 26’.
- the intermediate structures 8 are cut from each of the sections 26, 26’ by using a knife.
- the intermediate structures 8 are cut from each of the sections 26, 26’ by using a saw.
- the intermediate structures 8 are cut from each of the sections 26, 26’ by using a laser cutter.
- the intermediate structures 8 are cut from each of the sections 26, 26’ by using a water jet cutter.
- the in- termediate structures 8 are cut from each of the sections 26, 26’ by us- ing a heat cutter (hot cutting tool).
- Fig. 6A illustrates a portion of a prior art building construction element 102
- Fig. 6B illustrates a portion of a building construction ele- ment 2 according to the invention.
- the prior art building construction element 102 and the building con- struction element 2 comprises a first outer plate 4, a second outer plate 6 and a plurality of spaced apart interme- diate structures 8 each extending between: a) a first flange member 10 extending along and covering an inside portion of a first outer plate 4 and; b) a second flange member 10’ extending along and covering an inside portion of the second outer plate 6.
- PUR foam or PIR foam 18 has been filled into the space between the first outer plate 4 and the second outer plate 6.
- Fig 6C illustrates a flow chart illustrating steps of a method according to the invention. The first step is: “Determining the load bearing capacity of the PUR foam or PIR foam 18 filled into the space between the first wall struc- ture 14 and the second wall structure 16”.
- the second step is: “Determining the required load bearing capacity of the intermediate structures of the building construction element 2 in order to fulfil prede- fined requirements”
- the third step is: “Selecting the dimension of the intermediate structures 8 of the building construction element 2 in dependency of the determined required load bearing capacity of the intermediate structures 8”
- Fig. 7A illustrates internal forces FP and external forces FE exerted to structures of a building construction element 2 according to the inven- tion.
- the building construction element 2 corresponds to the one shown in and explained with reference to Fig. 6B.
- An external load causes an external force F E to be exerted to structures of a building construction element 2.
- the external force F E is transferred to the intermediate structures 8 that are load bearing structures.
- Fig. 7B illustrates internal forces FP and external forces FE exerted to structures of a building construction element 2 according to the inven- tion.
- the building construction element 2 differs from the one shown in and explained with reference to Fig.
- the compressive load at which a slender column will suddenly bend or buckle is called Euler's critical load, which is given by the following for- mula:
- Pcr Euler's critical load (longitudinal compression load on column)
- E Young's modulus of the column material
- I the minimum second moment of area of the cross section of the column (area moment of inertia)
- L the unsupported length of column
- K the column effective length factor
- Fig. 8A illustrates a cross-sectional view of a building construction ele- ment 2 according to the invention.
- the building construction element 2 is a floor element (e.g. a prefabricated floor element) intended for building constructions.
- the building construction element 2 comprises a sandwich structure comprising: a) several first outer plates 4 (only one is indicated) forming a first wall structure of the building construction element 2, b) several second outer plates 6 (only one is indicated) forming a sec- ond wall structure of the building construction element 2 and c) several partition plates 42 (only one is indicated) forming a third wall structure of the building construction element 2.
- the first, second and partition plates 4, 6, 42 are made of a fire resistant material (e.g. a material that contains concrete or is made of concrete. Alternatively, the material may contain plaster or be made of plaster).
- the sandwich structure comprises a) a number of reinforcement members 52 constituting flange members extending along the inside portion of a first wall structure and b) a number of and reinforcement structures 54 constituting flange members extending along the inside portion of a second wall structure.
- the reinforcement members 52 will typically cover the inside portion of the joints (not shown) of the first and third wall structure.
- the reinforcement structures 54 will typically cover the inside portion of the joints (not shown) of the second and third wall structure.
- the reinforcement members 52 and the reinforcement structures 54 constitutes a plurality of spaced apart intermediate structures. It may be an advantage that each of the reinforcement members 52 and the reinforcement structures 54 is a continuous section from a wind turbine blade as shown in and explained with reference to Fig. 5A and Fig. 5B.
- the building construction element 2 comprises a floor portion 50.
- the floor portion 50 comprises a heating portion 44 (e.g. comprising under- floor heating pipes) arranged on the top of the second outer plates 6.
- the floor portion 50 comprises a flooring 48 constituting the uppermost layer.
- the floor portion 50 comprises an intermediate portion 46 ar- ranged between the flooring 48 and the heating portion 44.
- the height H1 of the building construction element 2 is lower than the total height H2 of the building construction element 2 and the floor por- tion 50.
- the space between the first wall structure and second wall structure has been filed with a polyurethane (PUR) foam 18, 18’ or polyisocyanurate (PIR) foam 18, 18’.
- PUR polyurethane
- PIR polyisocyanurate
- the PUR foam or PIR foam 18, 18’ supports the in- termediate structure 52, 54 and hereby prevents the intermediate structure 52, 54 from bending.
- the intermediate structure 52, 54 are pairwise aligned (and thus extend along the same line). It may be an advantage to glue adjacent parts together since glue is typically stronger than stronger than the PUR foam or PIR foam 18, 18’.
- glue is typically stronger than stronger than the PUR foam or PIR foam 18, 18’.
- the density of the intermediate structures 52, 54 typically in the range 400-600g/l. In an embodiment, the density of the intermediate struc- tures 52, 54 is about 500 g/l. This resin will be available for screws do to fire classification.
- the mechanical properties of the intermediate structures 52, 54 are given by the following table.
- the PUR foam or PIR foam 18, 18’ will typically have a density in the range 35-50 g/l. In an embodiment, the PUR foam or PIR foam 18, 18’ has a density in the range 40-44 g/l. In an embodiment, the PUR foam or PIR foam 18, 18’ has a density of 41-43 g/l. In an embodiment, the PUR foam or PIR foam 18, 18’ has a density of 42 g/l.
- Fig. 8B illustrates a schematic perspective top view of the building con- struction element 2 shown in Fig. 8A. The foam 18, 18’ is not indicated in Fig. 8B.
- FIG. 8C illustrates another view of a building construction element 2 cor- responding to the one shown in Fig. 8A and Fig. 8B.
- the first outer plate 4 is attached to the reinforcement member 52 by using screws 56.
- the partition plate 42 is attached to the re- inforcement member 52 by using screws 56.
- the second outer plate 6 is attached to the reinforcement structure 54 by using screws 56.
- the first outer plate 4 is attached to the reinforce- ment member 52 by using glue.
- the partition plate 42 is attached to the reinforcement member 52 by using glue.
- the second outer plate 6 is attached to the reinforcement structure 54 by using glue.
- Fig. 9A illustrates a cross-sectional view of a building construction ele- ment 2 according to the invention.
- the building construction element 2 is a wall.
- the building construction element 2 comprises a sandwich structure comprising: a) several first outer plates 4 (only one is indicated) forming a first wall structure of the building construction element 2, b) several second outer plates 6 (only one is indicated) forming a sec- ond wall structure of the building construction element 2, c) several first partition plates 42 (only one is indicated) forming a third wall structure of the building construction element 2 and d) several second partition plates 42’ (only one is indicated) forming a third wall structure of the building construction element 2.
- the reinforcement members 52 will typically cover the inside portion of the joints (not shown) of the first and third wall structure.
- the reinforcement structures 54 will typically cover the inside portion of the joints (not shown) of the second and third wall structure.
- the reinforcement members 52 and the reinforcement structures 54 constitutes a plurality of spaced apart intermediate structures. It may be an advantage that each of the reinforcement members 52 and the reinforcement structures 54 is a continuous section from a wind turbine blade as shown in and explained with reference to Fig. 5A and Fig. 5B.
- the space between the wall structures has been filed with a polyure- thane (PUR) foam 18, 18’, 18’’’ or polyisocyanurate (PIR) foam 18, 18’, 18’’’.
- PUR foam or PIR foam 18, 18’ supports the intermediate structure 52, 54 and hereby prevents the intermediate structure 52, 54 from bending.
- the intermediate structure 52, 54 are pairwise aligned and are extending along the same line extending perpendicular to the plane of the outer plates 4, 6.
- FIG. 9B illustrates a schematic view of the building construction element shown in Fig. 9A.
- the first outer plate 4 is attached to the reinforce- ment member 52 by using screws 56.
- the partition plates 42, 42’ are attached to the reinforcement member 52 by using screws 56.
- the second outer plate 6 is attached to the reinforcement structure 54 by using screws 56.
- the first outer plate 4 is attached to the reinforce- ment member 52 by using glue.
- the partition plates 42, 42’ are attached to the reinforcement member 52 by using glue.
- the second outer plate 6 is attached to the reinforce- ment structure 54 by using glue.
- Fig. 9C illustrates a cross-sectional view of another building construction element 2 according to the invention.
- the building construction element 2 comprises a building construction element forming a wall as shown in Fig. 8A and a building construction element forming a floor element 80 that basically corresponds to the one shown in Fig. 9A.
- the building construction element as shown in Fig. 8A is fixed to the ground 68 by using several screw pile foundations 62 that are screwed into the ground 68. Accordingly, a ventilated portion 70 is provided un- der the floor element 80. Therefore, infiltration of water into the build- ing can be avoided.
- the floor element 80 is resistant to water and moisture.
- Each screw pile foundation 62 comprises a top part provided with a base plate.
- a plinth (e.g. made of composite) 72 is placed and rests on the baseplate of the pile foundation 62.
- a cover member 66 extends along the lateral side of the screw pile foundation 62.
- the cover member 66 comprises or is made of cement.
- the cover member 66 comprises or is made of concrete.
- reinforcement members 74 may be provided at the end portion of the floor element 80.
- An outer structure 60 is attached to the end portion of the floor element 80.
- the reinforce- ment members 74 are made of composite material.
- the wall is placed on reinforcement members 76.
- these reinforcement members 76 are made of composite material. It may be advantageous that an elastic joint material 78 is used as a joint between the wall and the floor element 80.
- Fig. 10A illustrates a cross-sectional view of two building construction elements 2 according to the invention.
- the leftmost building construc- tion element 2 is a flooring element comprising a first outer plate 4 and a second outer plate 6 made of a fire-resistant material.
- the space between the first outer plate 4 and a second outer plate 6 has been filed with a polyurethane (PUR) foam 18 or polyisocyanurate (PIR) foam 18.
- PUR polyurethane
- PIR polyisocyanurate
- the leftmost and the rightmost building construction element 2 comprises an end member 84 made of PUR or PIR having a density large enough to allow screws 56 to be screwed into and hereby be lockingly received by the end member 84.
- the leftmost building con- struction element 2 comprises an angled attachment member 82 de- signed to receive a corresponding angled attachment member 82’ of the adjacent rightmost building construction element 2.
- the rightmost building construction element 2 comprises an end mem- ber 84’ made of PUR or PIR having a density large enough to allow screws 56 to be screwed into and hereby be lockingly received by the end member 84’.
- Fig. 10B illustrates a cross-sectional view of the building construction elements shown in Fig. 10A in an assembled configuration.
- a closing plate 86, 86’ made of a fire-resistant material closes the joint portion between adjacent building construction elements.
- Fig. 10C illustrates a perspective of a floor comprising a plurality of building construction elements 2 according to the invention.
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Abstract
L'invention concerne un procédé de fabrication d'un élément de construction de bâtiment (2'), le procédé comprenant : la formation de chacune d'une première et d'une seconde structure de paroi (14 ; 16) à partir d'au moins une première et une seconde plaque externe (4, 4', 4" ; 6, 6', 6"), respectivement ; l'agencement d'une pluralité de structures intermédiaires espacées (8) pour s'étendre entre des premier et second éléments de bride (10 ; 10') s'étendant chacun le long et recouvrant une partie intérieure des première et seconde structures de paroi, respectivement ; le remplissage de mousse de polyuréthane (PUR) ou de mousse de polyisocyanurate (PIR) (18) dans l'espace entre les première et seconde structures de paroi ; la détermination de la capacité de support de charge de la mousse de PUR ou de la mousse de PIR remplie dans l'espace ; la détermination de la capacité de support de charge requise des structures intermédiaires pour satisfaire une ou plusieurs exigences prédéfinies associées à la capacité de support de charge de l'élément de construction de bâtiment ; et la sélection de la dimension des structures intermédiaires en fonction de la capacité de support de charge requise déterminée des structures intermédiaires. Grâce à ce procédé, il est possible de réduire les dimensions des structures intermédiaires et d'assurer en même temps que la résistance globale de l'élément de construction de bâtiment satisfait aux exigences prescrites.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DKPA202330064 | 2023-06-04 | ||
| DKPA202330064 | 2023-06-04 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2024251336A1 true WO2024251336A1 (fr) | 2024-12-12 |
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ID=93795100
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/DK2024/050135 Ceased WO2024251336A1 (fr) | 2023-06-04 | 2024-06-03 | Procédé de fabrication d'un élément de construction de bâtiment et élément de construction de bâtiment |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2024251336A1 (fr) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2450994A (en) * | 2007-07-11 | 2009-01-14 | William Patrick Smee | A structural insulated panel |
| EP2348161A2 (fr) * | 2010-01-26 | 2011-07-27 | Mjosutvikling As | Système modulaire pour la construction de maisons |
| US20200141118A1 (en) * | 2014-06-28 | 2020-05-07 | Kenneth R. Kreizinger | Frame Supported Ribbed Foam Composite Panel |
| EP3652388B1 (fr) * | 2017-07-10 | 2021-08-25 | Amovido A/S | Système de construction de bâtiment |
| US20210381237A1 (en) * | 2020-06-03 | 2021-12-09 | Patricia Mary Livingstone | Structural modular building panel, wall, and building system |
| WO2022114959A1 (fr) * | 2020-11-30 | 2022-06-02 | Holland Composites B.V. | Ensemble composite léger renouvelable |
-
2024
- 2024-06-03 WO PCT/DK2024/050135 patent/WO2024251336A1/fr not_active Ceased
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2450994A (en) * | 2007-07-11 | 2009-01-14 | William Patrick Smee | A structural insulated panel |
| EP2348161A2 (fr) * | 2010-01-26 | 2011-07-27 | Mjosutvikling As | Système modulaire pour la construction de maisons |
| US20200141118A1 (en) * | 2014-06-28 | 2020-05-07 | Kenneth R. Kreizinger | Frame Supported Ribbed Foam Composite Panel |
| EP3652388B1 (fr) * | 2017-07-10 | 2021-08-25 | Amovido A/S | Système de construction de bâtiment |
| US20210381237A1 (en) * | 2020-06-03 | 2021-12-09 | Patricia Mary Livingstone | Structural modular building panel, wall, and building system |
| WO2022114959A1 (fr) * | 2020-11-30 | 2022-06-02 | Holland Composites B.V. | Ensemble composite léger renouvelable |
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