MODULAR COMPONENT FOR THE PRODUCTION OF BUILDING STRUCTURES WITH UNIFORM INSULATING PROPERTIES

Abstract: A modular component for the production of building structures with uniform insulating properties comprises a substantially flat shaped modular insulating element (1, 20) made of thermoplastic material and with longitudinal side edges, joining means (7, 8, 7', 8') provided along said longitudinal side edges for coupling with similar adjacent modular elements so as to form a substantially continuous insulating panel which is devoid of thermal bridges, anchoring means (9, 10, 11, 12) provided on at least one large flat side of the modular element (1, 20) and extending along a direction that is substantially perpendicular to the plane on which the main modular element (1, 20) lies in order to allow its anchoring to a filling material (16, 16', 16'') of the wall structure. The modular element (1, 20) consists of a portion of thermoplastic material extrusion provided with at least one longitudinal compartment or cavity (2).

Description: MODULAR COMPONENT FOR THE PRODUCTION OF BUILDING STRUCTURES WITH UNIFORM INSULATING PROPERTIES FIELD OF THE INVENTION The present invention relates to the field of modular components employed for building structures, particularly of extruded thermoplastic components to be used as insulating and supporting members for the production on site or prefabrication of sound barrier panels used in buildings. BACKGROUND OF THE INVENTION Conventional systems for insulating building or wall structures or concrete panel prefabs are known, and these essentially consist of panels or layers of insulating materials such as for example expanded polystyrene or polyurethane foam, located within the cement or concrete casting. A major shortcoming of said known insulating systems is that they do not allow a total riddance of thermal bridges as prefabricated panels are at times interrupted by concrete ribs or support curbs. In correspondence with such interruptions there are often found to occur condenses and moulds. Moreover the polystyrene insulating panels may give rise to cracks, crevices and disjunction in and from the filling material wherein they are submerged. It is furthermore known a vertical thermoplastic modular component type which is extruded and has a box-like cross-section, which is capable of being joined with other similar units in order to build complete walls, which is provided with a first series of hollow compartments that are capable of receiving the concrete casting on the site, as well as a second series of compartments that are located parallel to the first series and that are capable of hosting an insulating material. In other words, such a known modular component forms a sort of formwork for the structure to build. A modular component of this type is disclosed in International PCT Patent Application N° WO/97/32095. This type of modular components known in the art are usually made of a thermoplastic material and by extrusion of synthetic resins that have previously been charged with glass fibres or alike. The material preferably used is of a fireproof type and the modular elements can be coated on their outside surfaces by layers of a high resistance plastic material in order to enhance its mechanical features. A drawback of said components for building structures is their relative complexity that involves the employment of rather complex extrusion processes and finishing processes for their production. In order to achieve a good partition of the concrete in the several compartments that the members comprise, mainly in case of very long modular elements, it is necessary to produce a certain number or openings in the separation walls in order to obtain a uniform distribution of the concrete during laying. All this contributes to the increase in the production costs of the components themselves. A further drawback of those building structures wherein said known modular member components are present is that there are found to occur discontinuities in correspondence with the areas joining adjacent panels, with the concurring likelihood to have infiltration on account of the fact that the concrete has in fact not a continuous surface. Other important drawbacks are closely associated with the aesthetic aspect of the walls or of other wall structures that are built using these panels. In fact, after they are put in place, the main plastic sides remain outside and the discontinuities found in correspondence with the joining areas between the components are altogether still visible. Moreover, in case of a severe and sudden shock suffered by one side of a loft building built using these elements and caused for example by a heavy industrial vehicle, the damage may not be repaired resorting to the conventional means currently used in the building field. Furthermore the said components cannot be either be easily varnished or painted as it is the case for masonry surfaces. Therefore all these factors contribute to constraining the success of said modular components on the market among the traditional customers that are handicraft and industrial enterprises. Besides what mentioned above, there is also found that common people reject buildings made with these synthetic materials on account of them giving the unpleasant feeling to be literally living in a plastic box, and this happens more frequently in those countries where the building materials traditionally used are stone or stone-based. DETAILED DESCRIPTION OF THE INVENTION The most important object of the present invention is to propose a modular component for the production of wall structures whereby it is possible to obviate the above mentioned drawbacks, in particular that is easy to accomplish and put in place. A more specific object of the present invention is to propose a modular component for the insulation of wall structures that suppresses or reduces any thermal bridges that form between adjacent insulating panels, creating a wall structure that has substantially uniform insulating properties. A further object of the present invention is to propose a modular component to be used for building prefabricated panels or wall structures with a more pleasant aspect and features that result to be more easily acceptable by common people, as finishing at the surface levels where the plastic material is allowed to be evident can be avoided, in case this is what the customer aims at, and that makes it possible moreover to repair or restore the walls in case of impacts or damages. The above objects as well as others that will be more evident from the reading of the present specification are accomplished according to claim 1 by a modular component for the uniform insulation of wall structures, characterised in that it comprises a substantially flat shaped main body having longitudinal end edges, said main body being provided with joining means located along said longitudinal edges, aimed at the mutual coupling with similar adjacent modular components so as to form a substantially continuous insulating panel that is devoid of thermal bridges, anchoring means being formed on said main body for its stable anchoring to the concrete or filling material volume which the wall structure within which the said component is found is provided. By dint of said configuration, the modular component makes it possible to accomplish the production of wall structures having substantially uniform insulating properties and devoid of thermal bridges, these accountably being more cost-effective to be put in place, and, once finished, better looking and requiring a less committing maintenance. According to a further form of embodiment of the present invention, there is found to be provided a method for the production of wall structures comprising insulating panels obtained by assembling modular components of the above mentioned type, which comprises the following steps: a) assembly of at least an insulating panel having a predetermined length and obtained by mutual coupling of a plurality of modular components according to one or more of claims 1 to 1 2; b) mounting a formwork consisting of a pair of side walls which are substantially parallel and insertion of said at least one insulating panel into a substantially intermediate position in between said side walls; c) Fitting of possible metal reinforcement members such as bars, washers or meshes in the portion or portions located between said at least one insulating panel and theformwork side walls. d) Concrete or another filling material casting into the interstices existing between said at least one insulating panel and the side walls of said formwork; e) Drying of the concrete; f) Disassembling of the formwork and exposure of the finished wall structure. SHORT DESCRIPTION OF THE DRAWINGS Further features and advantages of the present invention will be more evident from the reading of the following detailed description of some preferred forms of embodiment by way of not limiting examples, of a modular component for wall structures with uniform insulating properties, illustrated by way of not limiting example with reference to the appended drawings where: Fig. 1 shows a perspective view of a first embodiment of a modular component according to the present invention, before it is put in place; Fig. 2 shows a perspective view of a second embodiment of a modular component according to the present invention before it is put in place; Fig. 3 shows a perspective view of a third embodiment of a modular component according to the present invention before it is put in place; Fig. 4 shows a perspective view of a portion of panel obtained from joining several modular components according to the present invention, before it is put in place; Fig. 5 shows a perspective view of a portion of panel obtained from joining several structural elements according to a second form of embodiment of the present invention before it is put in place; Fig. 6 shows a cross-sectional view of a portion of wall structure obtained from modular components according to the first form of embodiment shown in Figure 1 ; Fig. 7 shows a cross-sectional view of a portion of an alternative form of embodiment of the wall structure obtained from modular components according to the second form of embodiment illustrated in Figure 2; Fig. 8 is a cross-sectional view of a portion of a further alternative form of embodiment of the wall structure obtained from modular components according to the second form of embodiment shown in Figure 2; Fig. 9 shows a cross-sectional view of a third alternative form of embodiment of a portion of wall obtained from structural elements according to a third form of embodiment of the present invention after laying. Fig. 10 shows a cross-sectional view of a further embodiment of a modular component with sliding joining means; Fig. 1 1 shows a cross-sectional view of a further embodiment of a modular component with sliding joining means; Fig. 12 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 1 ; Fig. 1 3 shows a cross-sectional view of a further embodiment of a modular component with transversely fitting joining means; Fig. 14 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 3; Fig. 1 5 shows a cross-sectional view of a further embodiment of a modular component similar to that of Fig. 1 3; Fig. 1 6 shows a cross-section view of a portions of wall structure incorporating several modular components shown in fig. 10; Fig. 1 7 shows a cross-section view of a portion of wall structure incorporating several modular components shown in fig. 1 1 ; Fig. 1 8 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 2; Fig. 1 9 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 3; Fig. 20 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 14; Fig. 21 shows a cross-section view of a portion of wall structure incorporating several modular components shown in Fig. 1 5; Fig. 22 shows a perspective view of a wal structure obtained from a panel whose portion is shown in Figure 4. DESCRIPTION OF SOME PREFERRED FORMS OF EMBODIMENT With particular reference to Figure 1 , a first form of embodiment is shown of the modular component according to the present invention, altogether identified by reference numeral 1 , essentially consisting of a portion of extruded profiled thermoplastic material, a PVC resin for example. Generally speaking modular component 1 may have a range of sections and sizes, depending on the type of building aimed at, and it can be cut to size when it is put in place on the building site or at the workshop before it is hauled to the site. Preferably, modular component 1 comprises a substantially flat shaped central body 2 with its main sides 3, 4 substantially opposite to each other and parallel to a main structural plane H, joined by two end sides 5, 6 which are substantially perpendicular to sides 3, 4. Thus, faces 3, 4 and edges 5, 6 end up forming an interstice 2' that may be either be left empty of filled with an insulating material, a synthetic resin such as polystyrene or foamed polyurethane for example, so as to improve the overall thermal and/or sound insulating properties of the component. Each of the modular components 1 may be provided with respective joining means 7, 8 along its end edges 5, 6, for the mutual coupling with other similar components, identified with reference numerals 1 ', 1 ", so as to form an insulating panel P having indefinite size, according to the needs, and conferring a substantially uniform and continuous insulation, moreover free of thermal bridges in the joining area. In a preferred form of embodiment, joining means 7, 8 may consist of respectively male and female members that can be coupled by sliding. For instance, in correspondence with the end edge 5, longitudinal protrusions 7' and 7" may be provided which are substantially opposite to each other and can be fitted into grooves 8', 8" by a sliding motion, said grooves being formed on sides 3, 4 and close to longitudinal end edge 6. Alternatively, joining means 7, 8 may have any complementary form whatsoever, provided that it is capable of mutually joining adjacent modular components 1 , 1 ', 1 " by engagement, along their respective longitudinal end edges. According to the present invention, central body 2 is provided with members for a stable anchoring to the concrete mass or to any filling material whatsoever that makes up the wall structure. In particular, said anchoring members may be made of stiffening ribs 9, 10, 1 1 , 1 2 that extend towards the outside starting from one or both main sides 3, 4 of the modular component on planes that are substantially perpendicular to the H main structural plane and along a longitudinal direction. When the wall members M are put in place or at the stage when the prefabricated panels are produced, said stiffening ribs 9, 10, 1 1 , 1 2 are submerged into concrete. In turn, stiffening ribs 9, 10, 1 1 , 1 2 may advantageously be provided with longitudinal protrusions 1 3, 14, 14, 1 5 that extend on a plane that is substantially parallel to the main structural plane H, in order to improve the overall anchoring conditions and avoid any possible detachments of the concrete. As shown in Figure 2, stiffening ribs 9, 10 may be provided on just one side 3 of body 2, in case the opposite face is intended to be left exposed and completely devoid of stiffening ribs. It is furthermore possible to provide a certain variable number of stiffening ribs according to the specific needs, as well as it is possible to vary the distance between stiffening ribs and their extension towards the outside. Figure 3 shows an alternative form of embodiment of component 1 wherein stiffening ribs 9 and 10 are regularly interrupted along their longitudinal direction, in order to achieve a better partition of the concrete during casting, in so doing avoiding the possibility to have bad looking voids on the wall. There are also found to be possible to produce members provided with both continuous and discontinuous stiffening ribs. This specific form of embodiment is particularly recommended whenever it is necessary to position the component within wall structures on horizontal planes, or transversally in prefabricated panels. Figures 4 and 5 schematically show portions of panels P each of them formed by the assembly of several modular components 1 , 1 ', 1 " that are joined by male and female joining means 7, 8. In such a way it is possible to join a predetermined number of modular components in a stable sort of way, in so doing obtaining a panel P having the desired width. Figure 6 shows a first alternative form of embodiment of a wall obtained by the joining of structural elements 1 , that further contain filling material at the interstice 2' in this specific alternative form of embodiment. Modular component 1 is placed between the side walls of a traditionalformwork which is not shown by the drawings, where concrete 1 7 is cast and reinforced with iron bars or meshes 1 8. In such a way there is found to be created a compact wall structure M, having a homogeneous exterior look and furthermore devoid of outside plastic surfaces. Wall structure M that results from disassembling the formwork has a more pleasant exterior aspect and can be easily painted or finished as desired. Moreover, wall insulation, accomplished thanks to the air space or the insulating material placed in the interstice 2', effectively insulates the two portions of concrete 1 7 and 1 7', avoiding any thermal bridge whatsoever in correspondence with the panel P component joints. Finally, the occurrence of the anchoring elements and of the relative protrusions allows to position the insulating panel P between the formwork walls in a handy and precise fashion. A further advantage of the present invention is that there is found to arise the possibility to resort to lower quality materials as after putting in place none of the portions of the members can be seen from the outside. Moreover, such a type of prefabricated panels or wall structures are more easily accepted by common people because they are more similar to traditional building structures. Figure 7 shows a further operating alternative form of embodiment of a wall structure M wherein side 3 of body 2 is the surface of insulating panel P and is bound to remain outside, whereas the opposite face 4 is bound to cooperate with the concrete. Such a solution may turn out to be advantageous when some of the features of the thermoplastic materials are to be exploited, such as endurance to weathering, in order to obtain the outside wall of a building with very high and fine surface finishing and also provided with a stable colouring. In such a case, for the forming of the structure a formwork made of just one exchangeable wall may be used, whereas the second parallel wall is made of the insulating panel P itself that is useful in containing and constraining the concrete. This alternative form of embodiment is very advantageous even for the production of covering surfaces to be used in buildings or roofs of the ventilated or insulated types. The third alternative operating form of embodiment shown in Figure 8 allows to obtain a wall structure M having both exterior surfaces consisting of the outside surfaces of two panels P, P' formed by respective modular components. The concrete is placed into the interstice formed by the two panels P, P' and it acts as a fixed form work. The fourth alternative operating form of embodiment shown in Fig. 9 is a solution to all those cases where the wall structure does not necessarily have to have extremely enhanced insulating features. In fact, in this alternative form of embodiment, panels P" are formed by joining components 20 that are substantially plate shaped rather than box shaped. Furthermore side 2 of panel P" which is turned towards the outside consists of the very exterior surface of modular components 20. Fig. 10 to 1 2 show several embodiment of modular component with one or two layers of insulating material 2' in which the joining means are shaped so as to be slidably coupled to each other along a direction that is substantially parallel to the longitudinal edges of the component. Fig. 13 to 16 show several embodiments of modular components with one or two layers of insulating material 2' in which the joining means are shaped so as to be transversely coupled to each other along a direction that is substantially perpendicular to the longitudinal edges of the component. In all those cases wherein the outside surface or surfaces of the thermoplastic panels are left exposed after being put in place, it is appropriate to employ thermoplastic materials whose properties comprise endurance to ageing, to fire or to other aggressive agents. Obviously the structural elements may be manufactured with several different sizes and can be employed both in their horizontal and vertical position, in accordance with the specific type of building to be manufactured. The production of walls or wall structures comprising modular thermoplastic components according to the present invention is accomplished by dint of one of the methods detailed below: A panel P is assembled first by mutually joining several modular thermoplastic components 1 in accordance with the present invention. If necessary panel P is cut down to size. A formwork which is known in the art is then built, said formwork having plastic, wood or metal walls, wherein assembled panel P is inserted employing the components 1 of which above. Metal reinforcements are then placed, said metal frames being of the reinforced-concrete rod or mesh types in the space between panel P and the formwork walls, and the concrete is then cast into said space. The time necessary for drying is then allowed after which the formwork is disassembled. At the end of this process a wall or wall member is obtained such as that shown in figure 6. In case one of the formwork walls is made from the panel consisting of the modular elements according to the present invention, the production process is similar to that detailed above, save the fact that just the second formwork wall is disassembled after the concrete has set. Such an alternative process yields to a wall or wall member of such a type as that shown in Figures 7 or 9. In case the wall structure has both walls consisting of panels P', P" obtained by the assembly of components 1 according to the present invention, in comparison with the above described method, there is found to arise the difference in that the formwork walls both consist of the same panels P', P", therefore at the end of the process there is no need for theformwork to be disassembled, as it eventually integrates to become a portion of the wall structure. According to the present invention the process for the production of prefabricated concrete panels comprising modular thermoplastic components may be the following. A first layer of concrete is first laid on the planes or tables traditionally used for the production of prefabricated panel, preferably of a vibrated type, and placed horizontally. After that a metal mesh or another suitable reinforcement material is laid horizontally on the concrete layer. Then a second concrete layer is laid whereon panel P formed by the joining of a plurality of modular components is then placed. Panel P is adjusted so as to let supporting ribs 9, 10, 1 1 , 1 2 sink into the concrete in order to enhance anchoring. A third concrete layer is then cast, said concrete layer having such a minimum thickness as to allow covering of supporting ribs 9, 10, 1 1 , 1 2. After that the mesh or other concrete reinforcement members are placed and the surface is covered with the amount of concrete needed in order for the desired thickness of the prefabricated component to be achieved. The upper side of the panel is then finished on its surface, resorting to methods known in the art. After the concrete has sufficiently set, the panel is removed from the table.

Claims: CLAIMS 1 . Modular component for the production of building structures with uniform insulating properties, characterised in that it comprises a substantially planar main body (2) having longitudinal end-edges (5,6), said main body (2) being provided with joining means (7, 8, 7', 8') located along said longitudinal edges, for the mutual coupling with similar adjacent modular components ( V, 1 ") so as to form a substantially continuous insulating panel (P) free of thermal bridges, anchoring elements (9, 10, 1 1 , 1 2) being formed on said main body (2) for the stable anchoring to the concrete mass ( 1 6, 1 6', 1 6") or to the wall structure (M) filling material in which the component is fitted. 2. Modular component according to claim 1 , characterised in that it consists of a portion of extruded thermoplastic material provided with at least one substantially planar side (3, 4) that is parallel to a main extension (H). 3. Modular component according to claim 2, characterised in that said main body (2) is substantially box shaped with at least two planar sides (3, 4) at a mutual distance and substantially parallel to each other and to said main extension plane (H) so as to form at least one longitudinal cavity or compartment. 4. Modular component according to one or more of the preceding claims, characterised in that said anchoring means (9, 10, 1 1 , 1 2) consist of stiffening ribs extending along a longitudinal direction, on planes that are substantially perpendicular to said main extension plane (H). 5. Modular component according to claims 3 and 4, characterised in that said anchoring means (9, 10, 1 1 , 1 2) extend towards the outside starting from only one of the planar sides (3,4) of said main body (2). 6. Modular component according to claim 2, characterised in that said anchoring means (9, 10, 1 1 , 1 2) extend towards the outside starting from both flat sides (3, 4) of said main body (2). 7. Modular component according to claim 4, characterised in that said stiffening means forming said anchoring means (9, 10, 1 1 , 1 2) are provided with side protrusions or tongues ( 1 3, 14) in order to promote a stable anchoring of the component to the mass of filling material ( 1 6, 1 6', 1 6") of the wall structure (M). 8. Modular component according to claim 4, characterised in that said protrusions (9, 10, 1 1 , 12) are substantially parallel to said main extension plane (H) and substantially have the same width along their entire longitudinal extension. 9. Modular component according to claim 4, characterised in that said stiffening ribs (9, 10, 1 1 , 1 2) have interruptions along their longitudinal direction. 10. Modular component according to claim 1 , characterised in that said joining means (7, 8) comprise respectively male (8', 8") and female (7', 7") members. 11. Modular component according to claim 1 0, characterised in that said joining means (7, 8) are shaped so as to be slidingly coupled along a direction that is substantially parallel to said longitudinal edges. 12. Modular component according to claim 10, characterised in that said joining means (7', 8') are shaped so as to be side-by-side coupled along a direction that is substantially perpendicular to said longitudinal edges. 13. Modular component according to anyone of preceding claims 1 to 7, 9, 1 0, characterised in that an insulating material of a natural or synthetic type is fitted into the longitudinal cavity or cavities (2') of said main body (2). 14. Method for the production of building structures with uniform insulating properties, comprising the following steps: a) assembling at least one insulating panel (P) having a predetermined length and obtained by the mutual coupling of a plurality of modular components (1 , 1 ', 1 ") according to at least one of claims 1 to 12; b) mounting a formwork comprising at least a pair of substantially parallel side walls and fitting said insulating panel (P) between said parallel side walls so as to have it interposed; c) positioning any metal reinforcement members ( 18) such as bars, washers or nets in the region or regions located between said insulating panel (P) and theformwork side walls; d) concrete casting (17) or casting of another filling material into the interstices formed between said insulating panel (P) and the side walls of saidformwork; e) drying of the concrete; f) disassembling the formwork and exposure of the finished building structure. 15. Method for the production of building structures having uniform insulating properties comprising the following steps: a) assembling a pair of insulating panels (P\ P") having a predetermined length and obtained by the mutual coupling of modular components according to at least one of claims 1 to 1 2; b) assembling a formwork consisting of a couple of substantially parallel side walls, one of said side walls consisting of one of said insulating panels, and fitting of the other insulating panel of said couple into the interstice which is so formed; c) fitting metal reinforcement members of the bar or mesh type into said interstice; d) concrete casting into said interstice; e) drying of the concrete; f) disassembling the formwork by detachment of just the side wall that is not part of said insulating panel. 16. Method for the production of building structures having uniform insulating properties, comprising the following steps: a) assembling a pair of insulating panels having a predetermined length, obtained by the mutual coupling of the modular components according to at least one of claims 1 to 1 3; b) assembling a formwork having a couple of substantially parallel side walls obtained from said couple of insulating panels; c) positioning metal reinforcement members of the bar or mesh type at the interstice within said formwork between said side walls; d) casting concrete into said interstice; e) drying said concrete. 17. Method for the production of prefabricated panels having uniform insulating properties, comprising the following steps: a) positioning horizontal working planes; b) spreading a first concrete layer onto said planes; c) positioning any metal reinforcement members ( 1 8) such as bars, washer or meshes horizontally onto said first concrete layer; d) spreading a second concrete layer; e) assembling at least one insulating panel (P) having a predetermined length and obtained by mutual coupling of a plurality of modular components ( 1 , 1 ', 1 ") according to at least one of claims 1 to 12. f) placing panel (P) horizontally onto said second concrete layer; g) adjusting the panel (P) so as to get the stiffening ribs (9, 10, 1 1 , 1 2) sink into the concrete in order to promote mutual anchoring; h) spreading a third concrete layer, having a thickness that is at least the same as the height of the stiffening ribs (9, 10, 1 1 , 1 2); i) placing a mesh or other reinforcement members onto the surface of said third concrete layer; I) spreading a fourth concrete layer having a suitable thickness; m) surface finishing the concrete surface; n) drying of the concrete; o) removing the panel from the plane.

Inventors: VELO ANGELO, VELO, ANGELO
Applicants: VELO ANGELO, VELO, ANGELO
Application year: 2000
Main classification: E04B2
IPC codes: B28B19, E04B2