WO2023200365A1

WO2023200365A1 - Wall panel

Info

Publication number: WO2023200365A1
Application number: PCT/RU2023/050022
Authority: WO
Inventors: Владимир Викторович ЛОЗЕНКО
Original assignee: Владимир Викторович ЛОЗЕНКО
Priority date: 2022-04-14
Filing date: 2023-02-10
Publication date: 2023-10-19

Abstract

The invention relates to the field of constructing prefabricated buildings, and more particularly to wall panels made of metal profiles for frame walls of buildings and structures. The present wall panel comprises an outer layer and an inner layer in the form of an outer wall and an inner wall of permanent shuttering attached to a frame, with a layer of filler disposed between the walls, the wall panel being finished with surfacing materials. The frame of the wall panel is in the form of a lightweight steel thin-walled structure comprised of metal profiles in the form of horizontal and vertical guides mounted around the perimeter of the frame and additional vertical posts and horizontal crossbars mounted inside between the horizontal and vertical guides of the frame. To connect the vertical posts and horizontal crossbars to one another at the points where they intersect, rectangular holes are provided in one of the profiles to allow another profile to pass therethrough. Further, the points at which the profiles of the frame of the wall panel are joined to one another are lined with a heat insulating material, and the permanent shuttering is mounted to the frame via a water and vapour proofing layer. The invention provides for the constructability of thermally efficient buildings, while reducing labour costs and labour intensity.

Description

WALL PANEL

DESCRIPTION OF THE UTILITY MODEL

The utility model relates to the field of construction of prefabricated buildings, namely to wall panels of frame walls of buildings and structures made of metal profiles [E04B1/18, E04B1/24, E04B1/62, E04B2/02, E04B2/56, E04B2/68, E04B2/84 ].

Known from the prior art is a RESIDENTIAL FRAME BUILDING, BUILDING FRAME AND BUILDING WALL [GB2325477 (A), publ.: 11.25.1998], including a frame rigidly connected to the base plate, and containing walls with window and door openings, and elements of interfloor floors , characterized in that the frame is made of vertical embedded boards with grooves at the level of each next floor, tied with horizontal jumpers fixed in the grooves, while the distance between the vertical embedded boards is chosen taking into account window and door openings, and the external and internal parts of the wooden frame are lined sheet material, forming a cavity that is filled with foam concrete.

The disadvantage of the analogue is the low functional suitability of buildings erected in the described way for use in cold climatic regions. Other disadvantages of the analogue are low reliability and load-bearing capacity, as well as a high risk of fire, due to the design features and materials used during construction.

The closest in technical essence is WALL FENCE FOR BUILDINGS AND STRUCTURES (OPTIONS) [RU79304 (U1), publ.: 12/27/2008], including outer and inner layers in the form of outer and inner walls of permanent formwork, fixed to a frame with spaced between the walls layer of filler, characterized in that the outer and inner walls of the permanent formwork are made, respectively, of slab or molded facing materials and of vapor-gas-permeable panels, while the frame is made of two rows with outer and inner rows of racks installed in rows with a step corresponding to each row, while the racks made composite with the length along the height of the building and interconnected by mounting ties, and on the outer and inner rows of racks, the outer and inner walls of the formwork are mounted, respectively, between which monolithic insulation is used as a filler, for example monolithic foam concrete, while shaped galvanized steel profiles are used as guides and racks, and adjacent racks of each row are connected by crossbars located with a technological step along the height of each row of racks. Molded facing materials are made of panels, for example, like siding with fastening the panels to the outer row of racks using screw connections, for example self-tapping screws, and facing slab materials are made in the form of facade slabs with smooth or tongue-and-groove edges and embedded elements in the form of U-shaped strip embedded inserts elements with legs protruding from the back side of the façade slabs in the form of flexible mounting strips, the vapor-gas-permeable layer is made of gypsum fiber or plasterboard panels, including moisture-resistant versions.

The main technical problem of the prototype is the high labor intensity of building buildings using the described method, due to the construction of walls directly from the base or ceiling, the use of cladding slab materials in the form of facade slabs and the absence of a heat-insulating layer in the structure, with the exception of the filler between the rows of the frame, which ultimately leads to an increase labor costs and labor intensity in the construction of buildings, as well as a decrease in their thermal efficiency, which excludes the possibility of constructing buildings using the described method in regions with cold climatic conditions. In addition, the described method involves performing all stages of the construction of a building at the site of its construction, which reduces the manufacturability of the building, which expresses the convenience and timing of its production.

The purpose of a utility model is to eliminate the shortcomings of the prototype.

The technical result of the utility model is to ensure the manufacturability of the construction of thermally efficient buildings with reduced labor costs and labor intensity.

The specified technical result is achieved due to the fact that a wall panel containing outer and inner layers in the form of outer and inner walls of permanent formwork, fixed to a frame with a layer of filler placed between the walls and finished with facing materials, characterized in that the wall panel frame is made in the form lightweight steel thin-walled structure made of metal profile formed by horizontal and vertical guides mounted along the perimeter of the frame and additional vertical posts and horizontal jumpers mounted inside between the mentioned horizontal and vertical guides of the frame, while connecting the vertical posts and horizontal jumpers to each other at the places of their intersection in one of the profiles Rectangular holes are made for another profile to pass through it, the joints of the wall panel frame profiles are lined with heat-insulating material, the permanent formwork is mounted to the frame on a hydro- and vapor barrier layer.

In particular, the metal profile is made in the form of a U- or C-shaped steel profile, with the side shelves of the horizontal and vertical guides facing inside the frame, the side shelves of the vertical racks placed between the shelves of the horizontal guides along them, the side shelves of the horizontal jumpers placed between the shelves vertical guides and/or vertical posts along them.

In particular, the wall panel has openings formed by additional vertical posts and horizontal lintels, the side profile flanges of which face the inner part of the frame with the possibility of forming door and/or window openings.

In particular, the frame of the wall panel is made multi-row, consisting of parallel oriented rows of the frame, connected to each other by transverse jumpers. In particular, the internal formwork is made of molded slab materials.

In particular, the external formwork is made of slab thermal insulation materials with a thickness of 30 to 300 mm, depending on the requirements for thermal protection of the building.

In particular, a layer of stone basalt wool was mounted on the external formwork to increase the thermal efficiency and sound insulation of the wall panel.

In particular, the hydro- and vapor barrier layer on the outside of the wall panel is mounted on a horizontal trust profile.

In particular, the internal space of the wall panel between the layers of internal and external formwork is filled with modified monolithic foam concrete with a density of at least 150 kg/m ³ .

In particular, the internal space of the wall panel is filled with loose insulation. In particular, holes are made in the vertical posts and horizontal lintels of the wall panel to allow the filler solution to pass through them to uniformly fill the internal space of the wall panel.

In particular, the internal space of the wall panel is filled with insulation with a density of at least 10 kg/ ^m3 .

Brief description of the drawings.

Figure 1 shows a general view of a wall panel filled with foam concrete.

Figure 2 shows a general view of a wall panel filled with slab insulating materials.

The figures indicate: 1 - horizontal guides, 2 - vertical guides, 3 - vertical posts, 4 - horizontal lintels, 5 - internal formwork, 6 - external formwork, 7 - hydro-, vapor barrier layer, 8 - filler, 9 - finishing materials .

Implementation of the invention.

The wall panel includes a metal frame, made in the form of a light steel thin-walled structure from a metal profile formed by horizontal 1 (see Fig. 1, 2) and vertical 2 guides mounted around the perimeter of the frame and additional vertical posts 3 and horizontal jumpers 4, mounted among themselves and inside between the mentioned horizontal 1 and vertical 2 frame guides.

The metal profile is made in the form of a U- or C-shaped steel profile, with the side shelves of the horizontal 1 and vertical 2 guides facing inside the frame.

In one embodiment, rectangular holes are made at the base of the vertical posts 3 and/or horizontal jumpers 4 for horizontal jumpers 4 and/or vertical posts 3 to pass through them, respectively.

In some embodiments, the wall panel may contain door and/or window openings formed by additional vertical posts and horizontal lintels, the side profile flanges of which face the inside of the frame. In one embodiment, the frame of the wall panel can be made multi-row, consisting of parallel oriented rows of the frame, connected to each other by transverse jumpers.

The connection of the frame elements to each other is made using both detachable and permanent connections.

To prevent the formation of freezing areas and improve the thermal insulation of the walls, the joints of the wall panel frame profiles are laid with heat-insulating material (not shown in the figures), for example, foam insulation, thermofol, etc. (not shown in the figures).

A permanent formwork is mounted to the frame of the wall panel on one and the other surface, containing an internal formwork 5 mounted on the side of the wall panel, which will subsequently serve as the internal wall of the building, and an external formwork 6 mounted on the opposite side of the wall panel, which will serve as outer wall of the building.

The inner 5 and outer formwork are mounted on a hydro- and vapor barrier layer 7, made, for example, of a membrane.

The internal formwork 5 is made of board materials, for example, cement particle board, oriented strand board, plasterboard, etc.

The outer formwork 6 is made of slab thermal insulation materials, for example, polystyrene foam, polystyrene foam, polyisocyanurate, etc., and the thickness of the outer formwork is selected based on the requirements for thermal protection of the building.

In one embodiment, a layer of stone basalt wool (not shown in the figures) can be mounted on the external formwork to increase the thermal efficiency and sound insulation of the wall panel.

In one embodiment, the hydro- and vapor barrier layer on the outside of the wall panel can be mounted on a pre-mounted horizontal trust profile (not shown in the figures).

The internal space of the wall panel between the layers of internal and external formwork is filled with filler 8, for example, modified monolithic foam concrete with a density of at least 150 kg/m ³ or bulk insulation (see Fig. 1), while in vertical posts 3 and/or horizontal lintels 4 of the wall panel, holes can be made for the filler solution 8 to pass through them to uniformly fill the internal space of the wall panel. In one embodiment, the filler 8 can be made of slab or roll materials, for example, mineral (stone) wool, expanded polystyrene, penoizol, cork, foam glass, ecowool, etc., with a density of at least 10 kg/m ³ , while this type of insulation is laid after installing one of the formworks 3 or 4 (see Figure 2).

Wall panels are designed based on the architectural design of the building.

To do this, based on the project, a design of wall panels is formed for each of the walls, including the partitions of the building separately, taking into account their size, shape, the presence of door and/or window openings, etc. When forming a project, the number of rows in the wall panel frame is taken into account. The dimensions, mainly the width of the metal frame profiles, are also specified and the mutual intersection of the vertical posts 3 and horizontal jumpers 4 is configured to subsequently form holes for the said posts 3 or jumpers 4 to pass through them. The relative position of the wall panels combined with each other in the building design is configured. Upon completion of the project, at least three layers are formed, one of which contains the elements of the metal structure of the wall panels, the second - the internal formwork 5, the third - the external formwork 6. Each of the elements of the layers is assigned an individual identification number.

Next, each of the layers is sent to production, where profiles are made according to the prepared project, cut to the dimensions specified by the configuration, rectangular holes and holes for filling with filler are cut out in them, the formwork is cut and cut, and an individual identification number is applied to each of the manufactured elements, assigned to them earlier during design.

Ready-to-install wall panel elements are assembled together using assembly operations, i.e. a metal frame is assembled from vertical 2 and horizontal 1 guides, vertical posts 3 and horizontal jumpers 4, and the mentioned elements 1-4 are mounted together with a detachable and/or permanent connection, for example, by welding, bolts, rivets, screws, etc. Next, when using foam concrete or loose insulation as a filler 8, install the inner 5 and outer 6 formwork and fill the internal volume of the wall panel with insulation 8. To ensure uniform filling, the wall panel is installed vertically before filling. In the embodiment of using slab or roll materials as filler 8 to fill the internal space of the wall panel, first install one of the formworks, internal 5 or external 6, fill the internal space between the profiles of the metal structure of the wall panel with filler 8 and then install the external formwork 6.

Before installing the inner 5 and outer 6 formworks, a hydro- and vapor barrier layer 7 is laid.

After the wall panels are assembled in production, they are transported to the building construction site and connected by assembly operations on a pre-installed foundation in accordance with the architectural design of the building, while before installing the wall panels, a layer of waterproofing is laid on top of the foundation.

After completing the installation work of the wall panels, the outer and inner walls are finished with finishing materials 9.

As an example of the implementation of the claimed utility model, we will show the option of using a wall panel for the construction of the basement floor of a building.

At the first stage, the foundation of the building is poured, for which a excavation is made in the ground with the required depth, width and configuration. The foundation is made as a strip foundation, in the form of a grillage, and can be made on a cushion, or reinforced with reinforcement.

At the second stage, after the foundation has hardened, it is waterproofed, and from the outside the foundation is additionally insulated with a heat-insulating layer, after which it is backfilled with soil and/or crushed stone.

At the next stage, wall panels are installed on the foundation in accordance with the architectural design of the building.

Next, a screed reinforced with reinforcement is poured onto the inside of the building being constructed. In some embodiments, when pouring the screed, it is thermally insulated and/or a heated floor pipeline is installed.

A blind area is cast outside along the foundation.

At the last stage, the external and internal walls of the building are finished. To do this, the outer and inner walls of the building are finished with finishing materials 9.

The outside of the wall panels can be finished with decorative materials or a ventilated façade can be mounted to them. The technical result of the utility model - ensuring the manufacturability of the construction of thermally efficient buildings with reduced labor costs and labor intensity - is achieved due to the fact that for the construction of a building according to an architectural design, including the placement of door and window openings, completed and ready-for-installation wall panels are manufactured, each of which includes a metal frame made in the form of a light steel thin-walled structure from a metal profile formed by horizontal 1 and vertical 2 guides mounted around the perimeter of the frame and additional vertical posts 3 and horizontal jumpers 4 mounted inside between the mentioned horizontal 1 and vertical 2 guides of the frame and non-removable inner 5 and outer 6 formworks, forming a closed volume filled with filler 8, while the outer formwork 6 is already made of slab heat-insulating materials, which eliminates the need to insulate the facade of the building and thus ensures quick assembly of the building by delivering ready-made wall materials to the construction site modules and their subsequent assembly using standard assembly operations.

Claims

UTILITY MODEL FORMULA

1. A wall panel containing outer and inner layers in the form of outer and inner walls of permanent formwork, fixed to a frame with a layer of filler placed between the walls and finished with facing materials, characterized in that the frame of the wall panel is made in the form of a light steel thin-walled structure made of a metal profile , formed by horizontal and vertical guides mounted along the perimeter of the frame and additional vertical posts and horizontal jumpers mounted inside between the mentioned horizontal and vertical guides of the frame, while to connect the vertical posts and horizontal jumpers to each other at the places of their intersection in one of the profiles, rectangular holes for another profile to pass through it, the joints of the wall panel frame profiles are lined with heat-insulating material, the permanent formwork is mounted to the frame on a hydro- and vapor barrier layer.

2. The panel according to claim 1, characterized in that the metal profile is made in the form of a U- or C-shaped steel profile, while the side shelves of the horizontal and vertical guides face inside the frame, the side shelves of the vertical posts are placed between the shelves of the horizontal guides along them, the side shelves of the horizontal jumpers are placed between the shelves of the vertical guides and/or vertical posts along them.

3. The panel according to claim 1, characterized in that it contains openings formed by additional vertical posts and horizontal lintels, the side profile flanges of which face the inner part of the frame with the possibility of forming door and/or window openings.

4. The panel according to claim 1, characterized in that the frame of the wall panel is made multi-row, consisting of parallel oriented rows of the frame, interconnected by transverse jumpers.

5. Panel according to claim 1, characterized in that the internal formwork is made of molded slab materials.

9

6. Panel according to claim 1, characterized in that the outer formwork is made of slab thermal insulation materials with a thickness of 30 to 300 mm, depending on the requirements for thermal protection of the building.

7. The panel according to claim 1, characterized in that a layer of stone basalt wool is mounted on the outer formwork to increase the thermal efficiency and sound insulation of the wall panel.

8. The panel according to claim 1, characterized in that the hydro- and vapor barrier layer on the outside of the wall panel is mounted on a horizontal trust profile.

9. The panel according to claim 1, characterized in that the internal space of the wall panel between the layers of internal and external formwork is filled with modified monolithic foam concrete with a density of at least 150 kg/m ³ .

10. The panel according to claim 1, characterized in that the internal space of the wall panel is filled with bulk insulation.

11. The panel according to claim 1 or claim 9, characterized in that the vertical posts and horizontal lintels of the wall panel have holes for the filler solution to pass through them to uniformly fill the internal space of the wall panel.

12. The panel according to claim 1, characterized in that the internal space of the wall panel is filled with insulation with a density of at least 10 kg/ ^m3 .