WO2009053765A1

WO2009053765A1 - Modular panel

Info

Publication number: WO2009053765A1
Application number: PCT/IB2007/002489
Authority: WO
Inventors: Alessandro Rupoli
Original assignee: Schnell House S.A.
Priority date: 2007-10-23
Filing date: 2007-10-23
Publication date: 2009-04-30

Abstract

The panel (1) comprises: a central core (2); two nets (3) between which said central core (2) is contained; retention means (6; 106) designed to retain said central core (2) in a pre-established position with respect to said nets (3), said retention means (6; 106) comprising areas (9; 109) for f itting reinforcement elements (10).

Description

"MODULAR PANEL" TECHNICAL FIELD

The invention relates to a modular panel, particularly suitable for the manufacture of reinforced concrete products.

PRIOR STATE OF THE ART

For some time now in the building trade, pre- assembled panels have been known and used made up of the coupling of a central core of insulating material, suitably shaped, but substantially in sheets, and two flat metal nets which enclose the central core between them.

These panels in fact have a "sandwich structure" and are normally installed to create the walls and the ceilings of a building which, afterwards, is covered with concrete, creating a building that can become "bearing" to form walls and ceilings of a bui lding . According to conventional practice, these walls and these ceilings are made in such a way as to be modular and easy to couple with other similar ones, by means of suitable joints, to make up a building technically defined as "with bearing partition walls" . In detail, to ensure there are no portions of metal reinforcement net that are not completely covered by the concrete casting because they are in direct contact with the surface of the insulating material, solutions have been devised that allow maintaining the central core slightly apart by a pre-set distance with respect to the metal nets, but fixed and substantially parallel with respect to these, so that this distance cannot change due to mutual slidings between the central core and the metal nets. Pratically, these known solutions consist in placing a number of spacer elements between the nets and the central core that are made integral with the nets and which are turned towards the central core so as to prevent contact between the nets and the central core and therefore leave the interspaces required for the cement to transit during the subsequent casting phase.

This characteristic is required because the concrete must fully cover the reinforcement wires. This way, the latter are insulated with respect to the outside and are protected against atmospheric agents, thus preventing the oxidisation of the iron and consequently the reduction of the resistant section of the wire itself and consequently the overall resistance of the entire building . During this phase, these interspaces are invaded by the concrete and allow this to insinuate itself between the meshes of the metal nets, covering the entire surface of these and becoming, with the gradual curing of the concrete, which causes their hardening, a single solid body in which the reinforcement nets are completely drowned in the concrete ensuring the minimum reinforcement covering layer required by the regulations, to form a structural part of a building "with bearing partition walls" or the like.

A modular panel of the previously described type is known by the European patent EP 0701647. According to this patent, the modular panel basically comprises a sheet-shaped central core made of insulating material, and two flat net elements that contain it between them and which are arranged parallel to the two larger faces defined by the central core. Between the two flat nets, transversal stitching elements are provided that cross the central core and which have their respective ends made integral with both nets. These transversal elements are arranged obliquely with alternate inclination with respect to the parallel position of the net planes, in such a way as to create a web of transversal elements in the whole modular panel which, reciprocally crossing each other according to contrasting oblique directions and crossing the central core, keep this fixed at a predetermined distance from the nets, preventing any sliding with respect to these and thus preventing the nets from coming into contact with the sheet of insulating material. The inclination and number of these transversal elements can vary according to need, its also being possible to achieve, according to a manufacturing variation of the patent EP 0701647, central core positions that are not symmetric with respect to the metal nets, meaning they are closer to one of the two with respect to the other.

According to a further alternative solution of EP 0701647, to replace the oblique transversal elements, equipping the nets with special feet, turned perpendicularly towards the central core and welded to the meshes of the nets themselves, is also considered.

In this case, transversal stitching elements are again considered between the metal nets arranged perpendicular to the faces of the central core, while the feet have predetermined lengths in relation to the distance to be kept between each net and the central core.

Another panel for the building trade is known by the patent IT 1.262.589 relating to a panel which, like the previous one, has a central core made of substantially sheet-shaped insulating material contained between two flat metal nets. In this case as well, spacer elements are provided to keep the central core away from the metal nets, which also have the function of stitching elements between the two nets and of elements resistant to the shearing stresses.

These spacer elements consist of a plurality of metal U-shaped reinforced concrete rods with two straight and parallel sections linked together at corresponding ends by a cross section which shapes a bend turned towards the central core: pratically, these U-shaped reinforced concrete rods have a substantially U shape. These U-shaped reinforced concrete rods are fitted crossways in the central core until the bends are resting on the flat faces of this, keeping it distanced and stopped with respect to the metal net s . The U-shaped reinforced concrete rods are fitted in the core in directions opposite to one another and are made integral with the respective metal nets in a known way, after the panel has been as sembled .

This state of the art does have some drawbacks. A first drawback is that the manufacture of the transversal stitching elements arranged sloping with respect to the nets requires the nets to be purposely designed in relation to the inclination of the transversal stitching wire, because this must find at its ends the elements of the net with which to join: consequently, this special design determines a considerable waste of time as regards panel preparation. A further drawback of this type of panel is that it is particularly difficult to manufacture due to the fact that the transversal joining wire has to cross a greater thickness of the central core thereby risking greater deviation from the theoretical trajectory, with the risk of not encountering the wire of the metal net on which it has to be welded.

Furthermore, because the welding operations are performed by automatic machines, the fact that they are inclined makes welding operations particularly complicated. Another drawback is that the solution considering the use of additional feet as well as the transversal stitching elements between the nets is very costly, calling for the realisation and repeated fixing to the nets of additional elements to keep the central core stable and distanced. Another drawback is that the fitting of the U- shaped reinforced concrete rods and their fixing to both the nets takes a substantially long time and requires crossing the central core, creating a metal bridge between the nets, these too made of metal, that enclose it and which, in the event of a high number of U-shaped reinforced concrete rods being used, can considerably reduce the effectiveness of the overall insulation provided by the central core.

A further drawback is that, however much the known panels can be reinforced in a differentiated way after the panel has been formed, meaning that areas of these that undergo higher stresses compared to areas that undergo less stress are strengthened, this operation is very complicated and hard to perform and, when all said and done, costly . OBJECTS OF THE INVENTION. One object of the invention is to improve the state of the art.

Another object of the invention is to make a panel, also suitable for use in the building trade, that permits maintaining the central core at a distance from the metal nets that contain it, with spacer elements that do not have to cross it. Another object of the invention is to make a panel also for the building trade that is easy and quick to make .

A further object of the invention is to make a panel also suitable for use in the building trade that can be reinforced in a differentiated way in different areas of this after the panel has been formed or already installed.

According to one aspect of the invention, a panel is provided for the building trade comprising: a central core; two nets between which said central core is contained; retention means designed to retain said central core in a pre-established position with respect to said nets, characterized in that said retention means comprise areas for fitting reinforcement elements. According to another aspect of the invention, a building structure is provided that comprises a panel comprising: a central core,- two nets between which said central core is contained; retention means designed to retain said central core in a pre-established position with respect to said nets, characterized in that said retention means comprise areas for fitting reinforcement elements. According to a further aspect of the invention, a method is provided for the manufacture of panels, comprising: arranging a substantially sheet-shaped central core of insulating material between two flat metal nets; placing in between said flat metal nets and said sheet-shaped central core retention means designed to retain said fixed central core with respect to said nets, characterized in that said placing in between comprises obtaining in said nets bends turned towards said central core, in such a way as to rest on the larger faces of this.

The panel and the method for the manufacture of panels therefore permit keeping the central core at predetermined distances with respect to the metal nets containing it, without the spacer elements crossing the central core and thus preventing the formation of undesired and harmful heat micro-bridges between the nets. Furthermore, the panel also permits reinforcing in a differentiated way different areas of the latter according to the stresses this has to withstand and keeping in position additional reinforcement rods without having to perform subsequent operations for their fixing. BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages will appear more evident from the description of an embodiment of a panel for the building trade, illustrated indicatively by way of non limiting example, in the attached drawings wherein:

Figure 1 is a schematic view from the top of a panel for the building trade according to the invent ion; Figure 2 is a cross section schematic view of the panel for the building trade of Figure 1, taken along a plane II-II of Figure 1 ;

Figure 3 is a view on an enlarged scale and interrupted of a detail of a panel for the building trade in a second possible embodiment. EMBODIMENTS OF THE INVENTION.

With particular reference to Figure 1, by 1 is generally indicated a panel, particularly suitable for the manufacture of reinforced concrete products, which comprises a central core 2, made of insulating material (see Figures 2 and 3) , which has a substantially flat sheet shape and which is closed in a sandwich between two metal nets 3, which are also flat, or substantially- such .

By insulating material is meant all the materials able to prevent heat and/or noise conduction.

The metal nets 3 comprise quadrangular meshes formed with iron rods 4 and 5 arranged according to directions substantially perpendicular with each other and which in the specific case are a transversal direction 4 and a longitudinal direction 5 respectively: consequently, hereinafter, the transversal rods will be indicated with the reference 4 while the longitudinal rods will be indicated with the re f erence 5.

According to a first version of the invention illustrated in Figure 3, in the rods 4 bends 6 are obtained that are turned towards the central core 2, deforming, for example by bending, or stretching at least sections of at least part of said longitudinal rods 4; the obtained bends 6 therefore comprise two curved sections 7 joined together by a section 8 ready for resting on the central core 2 and which joins them together. These bends 6 consequently shape, between the curved sections 7 and the joining sections 8, a number of cavities 9 in which can be placed, if necessary, further metal rods 10, arranged parallel to the rods 5.

For a person skilled in the field it is in any case easy to think of making what has been indicated above both on the longitudinal rods 5 and on the transversal rods 4, thus creating the bends 6 in order to add and keep in the correct position further reinforcement rods 10 parallel to these.

The bends 6 can be obtained according to desired distributions in the metal nets 3, so that, for example, they are aligned with each other, so as to be able to fit a desired number of further rods 10 to reinforce the panel 1 in the desired areas and according to performed structural calculations .

According to a further version of the invention, the bends, indicated in this case with the reference 106 (see Figure 2) , can be obtained by cutting segments of longitudinal rods 4 (or longitudinal rods 5) and shaping, for example by means of a bending operation, the cut segments so as to obtain the bends 106. The latter further shape two curved sections 107 and a joining section 108 of these, ready to be rested on the central core 2, more precisely on two parallel and opposite larger faces 102 of this .

In this case as well, each bend 106 forms a hollow seat 109 inside which a further reinforcement rod

10 can be arranged crossways.

In both versions of the invention, segments of rod

11 and 12 are also envisaged that join the two nets 3 together, crossing the central core 2 in a substantially perpendicular direction.

It is also possible, if expressly requested, to have the segments of rod 11 and 12 arranged sloping, as already indicated in the known technology . It should be noted that the nets 3 can be made by arranging the transversal rods 4 between the central core 2 and the longitudinal rods 5 (see Figure 3) : this makes it easier to spread layers of mortar for covering the surfaces of the panels 1 when these are installed.

According to a further version of the invention, the fitting and fixing is also considered, between the meshes of the nets 3, of the further additional metal rods 13, these not being considered by the structural calculation, along which, the bends 6 or 106 are obtained. The latter, as is shown in the Figures 2 and 3, have the two curved sections 7 and 107 of the same length, or substantially of the same length, in such a way that the seats 9 and 109 are substantially closed at the side and that the further rods 10 that can be fitted in these cannot escape from them.

The shape of the bends 6 or 106 can be any, open or closed, according to the specific requirements that a person skilled in the field can assess for every need .

Furthermore, it can have a profile shaped in such a way as to oppose the necessary support surface against the larger faces 102 of the central core 2 in order not to sink too much into the insulating material from which it is made in relation to the pressure applied during the realisation phases or during the transport and the installation of the panels themselves. The panel 1 is made as follows: the two metal nets 3 are first of all prepared obtaining in these the bends 6 or 106, both by bending or by cutting and subsequent shaping a predetermined number of meshes of the metal nets 3. The central core 2 is therefore positioned between two nets 3 and, by means of the bends 6 or 106, is kept at a pre-established distance from these, forming "IN" interspaces.

Afterwards, the segments of rod 11 and 12 are fitted crossways and these are made integral with the nets, for example, by means of weldings, bindings, gluing and other methods known to technicians in the field: this way the formation is completed of the structure of a panel 1, particularly, but not only, suitable for use in the building trade.

This panel 1 is installed and only before being covered with the concrete which envelops both the central core 2 and the nets 3 are the further reinforcement rods 10 fitted in the respective bends 6 or 106 chosen to reinforce the required areas of the panel 1.

These bends 6 or 106, having a substantially closed perimeter, permit maintaining the further rods 10 in their position during the covering of the panel 1 with the concrete.

The panel 1 and the method for making panels according to the invention also permit forming and installing a double panel, meaning a panel that comprises two panels 1, made according to the present invention, placed parallel with each other and advantageously connected by further transversal joining elements to keep them united at a desired distance. The double panel thus obtained acts in this case as a disposable reinforced and insulated form. The procedure for installing the double panel is the same as that previously described for a single panel, meaning, when the double panels are positioned and joined to form the building, the concrete is cast inside the volume delimited by the two cores 2 so as to obtain a reinforced partition wall and therefore with bearing and greater structural characteristics than those of the single panels.

Claims

CLA I M S

1) Panel particularly suitable for the manufacture of reinforced concrete products comprising: a central core (2) ; two nets (3) between which said central core (2) is contained; retention means (6; 106) designed to retain said central core (2) in a pre-established position with respect to said nets (3) , characterized in that said retention means (6; 106) comprise areas (9; 109) for fitting reinforcement elements (10) . 2) Panel according to claim 1, wherein said retention means (6; 106) are outside said central core (2) .

3) Panel according to claim 1, wherein said retention means comprise bends (6; 106) obtained in segments (4), (5) forming said nets (3) and turned towards said central core (2) .

4) Panel according to claim 3, wherein said bends (6; 106) comprise a first portion (7; 107) of mesh bent towards said central core (2), a second portion (8; 108) of contact with said central core (2), a third portion (7; 107) bent towards said mesh.

5) Panel according to claim 4, wherein said first portion (7; 107) and third portion (7; 107) are substantially the same.

6) Panel according to claim 4, wherein said second portion (8; 108) shapes a substantially rounded profile supporting said central core (2) and of jointed connection between said first portion (7; 107) and third portion (7; 107) .

7) Panel according to claim 6, wherein said second portion (8; 108) shapes a segment substantially parallel to a surface (102) of said central core (2) .

8) Panel according to claim 1, wherein said nets (3) comprise meshes that define outer surfaces turned opposite said central core substantially free from protrusions . 9) Panel according to claim 3, wherein said bends (6; 106) are obtained aligned to each other according to pre-set directions . 10) Panel according to claim 9, wherein said pre-set directions comprise transversal and/or longitudinal directions.

11) Panel according to claim 9, wherein said directions comprise oblique directions. 12) Panel according to claim 1 and 3, wherein said reinforcement elements comprise further rods (10) that can be fitted in said bends (6; 106) .

13) Panel according to claim 1, wherein said retention means comprise bends (6; 106) obtained in elements (13) that can be fixed to said meshes of said nets (3) and turned towards said central core (2) . 14) Panel according to claim 1, wherein said central core (2) is substantially sheet-shaped defining two parallel larger faces (102) .

15) Panel according to claim 1, wherein said central core (2) is made of insulating and/or noise non-conducting material .

16) Panel according to claim 1 and 14, wherein said nets comprise substantially flat metal nets (3) , so that they can be arranged substantially parallel to said larger faces (102) .

17) Product structure characterized in that it comprises at least one panel (1) according to any of the claims from 1 to 16.

18) Method for manufacturing panels, particularly suitable for the manufacture of reinforced concrete products comprising: arranging a substantially sheet-shaped central core (2) in insulating material between two flat metal nets (3) ; placing retention means in between said flat metal nets (3) and said sheet-shaped central core (2) for retaining said central core (2) fixed with respect to said nets (3) , characterized in that said placing in between comprises obtaining in said nets (3) bends (6; 106) turned towards said central core (2), in such a way to rest on the larger faces (102) of this. 19) Method according to claim 18, wherein said bends (6;

106) are aligned to each other according to pre-set directions .

20) Method according to claims 18 and 19, wherein reinforcement elements (10) are fitted in said aligned bends (6; 106) , in such a way to reinforce chosen areas of said panels (1) . 21) Method according to claim 18, wherein said obtaining comprises permanently deforming meshes of said nets (3) in such a way that said bends (6; 106) can be rested outside said central core (2) . 22) Method according to claim 18, wherein said obtaining comprises associating with said nets (3) elements (13) already having pre-shaped bends (6; 106) and turned towards said central core (2) .

23) Method according to claim 18, wherein said obtaining comprises: cutting meshes of said nets (3) obtaining cut segments; bending said cut segments forming bends (6;

106) turned towards said central core (2) . 24) Method according to any of the claims from 18 to 23, wherein panels (1) are joined together, so to obtain multiple panels.