Composite-material-based plate-reinforcement-material-integrated lightweight structural material, ship deck structure manufactured using same, and method for manufacturing composite-material-based plate-reinforcement-material-integrated lightweight structural material

Abstract

The invention discloses a plate reinforcing material integrated lightweight structural material based on a composite material and a ship deck structure manufactured by using the same. The composite-material-based plate-reinforcing-material-integrated lightweight structural material according to the present invention performs the function of a plate reinforcing material substantially by forming a plurality of protrusions at certain intervals below a flat plate portion, since the protrusions are integrally manufactured within the structure without a separate bonding process such as welding or bolting, thereby improving the strength of the plate reinforcing material. Therefore, the thin plate is ultra-light, thin in thickness and excellent in structural performance, can be manufactured into a large-span structure, can be used as a thin plate structure of a ship, and can also be widely used as a building material.

Description

Technical Field

[0001] The present invention relates to a composite material-based plate reinforcement material integrated lightweight structural material, a ship deck structure manufactured using the same, and a method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material, and in particular, relates to a composite material-based plate reinforcement material integrated lightweight structural material, which fundamentally solves the problem of thermal deformation of steel plate structural materials mainly used in ship construction due to welding of upper plates and plate reinforcement materials during the manufacturing process, greatly reduces the overall weight of the structure, simplifies the manufacturing process, and has excellent performance in shock absorption and noise reduction, a ship deck structure manufactured using the same, and a method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material. Background Art

[0002] Generally speaking, the main structural material used in ships is steel plate structural material composed only of metal. Figure 1 As shown, the conventional ship steel plate structural material is manufactured by welding a plate reinforcement material 20 composed of metal to an upper plate 10 composed of metal. At this time, the plate reinforcement material 20 is composed of a longitudinal girder 21 reinforcing the longitudinal structure and a transverse frame 22 reinforcing the transverse structure.

[0003] The conventional steel plate structural material is manufactured by first joining a metal plate serving as an upper plate 10, and then welding a plate reinforcing material 20 for longitudinal strength reinforcement thereon at intervals of 500 to 900 mm in a frame interval. However, when the plate reinforcing material 20 is welded to the upper plate 10 at close intervals as in the conventional method, the following problems occur.

[0004] (1) Thermal deformation caused by welding

[0005] The most fatal problem is the thermal deformation caused by welding. When welding the plate reinforcement material 20, the welding part is heated to about 1000 to 1500°C, and the heated steel plate will produce considerable stress and deformation during the cooling process. As a result, after welding the plate reinforcement material 20, the entire plate will inevitably bend with a deviation of tens of millimeters (mm) per meter (m), so the subsequent correction work will consume a lot of time and cost.

[0006] In particular, on a Pure Car Carrier (PCC), structural materials used for car decks or ship living area walls require a thin upper plate with a thickness of about 6 to 10 mm. If the structure is formed with a thin thickness like this, problems caused by welding deformation such as the upper plate itself being torn due to welding deformation, or being severely twisted so that it cannot be corrected by subsequent correction processes are more serious than in other areas.

[0007] At present, in order to prevent the above problems from occurring, a much thicker upper plate than required by the structure is used, or a large amount of time and cost is spent on subsequent processes to correct the thermal deformation. Therefore, a more fundamental solution is needed.

[0008] At the same time, laser welding is a welding method with much smaller thermal deformation than arc welding or gas welding commonly used in the shipbuilding field. Laser welding is a method of joining by focusing the light energy emitted by a laser source on the workpiece and melting the parent material. However, laser welding has limitations in generating enough electricity to melt the parent material, and its disadvantage is that the welding speed and weldable thickness are determined by the thermal conductivity of the metal and the gasification of the surface metal, not by electricity, so when a thicker parent material is applied, the welding efficiency will be greatly reduced.

[0009] It is generally believed that laser welding can reach 6mm, but in fact, the speed of laser welding will drop significantly when the thickness is above 4mm, so laser welding is generally applied to cases where the base material thickness is 3mm or less. In other words, it is not easy to apply laser welding to 6mm steel plates, which are generally known as the thinnest structures in shipbuilding. In addition, it takes considerable energy to melt the 6mm thick upper plate, and even in this case, the same welding deformation will occur when the relatively wide weld area cools, so there is not much advantage.

[0010] (2) Weight issue

[0011] Another disadvantage of conventional steel plate structural materials for ships is their excessive weight. Of course, the steel plate structural materials mainly used in ships are much lighter than reinforced concrete used in construction, but in terms of the importance of environmentally friendly ships, cost reduction, and labor cost reduction that have recently emerged, "ship lightweighting" is one of the biggest topics in the global shipbuilding and shipbuilding fields. Reducing the weight of a ship can reduce the energy required to propel the ship, so it can also reduce carbon emissions. In addition, ship lightweighting is also very important in ensuring the resilience of the ship.

[0012] In particular, in the case of a PCC having multiple decks, the center of gravity of the ship shifts upward due to the weight of the decks, greatly impairing the resilience of the ship. Therefore, it can be said that reducing the weight of the deck to achieve lightweighting of the ship is a crucial structural requirement.

[0013] (3) Low utilization rate as building material

[0014] Although the above-mentioned traditional steel plate structural material is much lighter than reinforced concrete and can achieve the same structural performance with a thinner thickness, it has not been widely used in the construction field. The biggest reason is the noise transmission characteristics of the steel plate. Since the entire structure of the steel plate structural material is composed of a single metal with a high density, it has better noise transmission ability than structural materials made of other materials when it is impacted. Therefore, it is rarely used as a construction material, especially a building floor material where the prevention of inter-floor noise is very important.

[0015] In addition, the thermal conductivity of steel plate structural materials is too high and is not suitable as a building material that emphasizes thermal insulation. The thermal conductivity of reinforced concrete is 1.6 to 2.0 W / mK, while the thermal conductivity of steel plates is 83 W / mK, which is very high. Having high thermal conductivity means that heat from the outside is transferred to the inside very quickly and easily, so it is very weak in terms of thermal insulation. Summary of the invention

[0016] Problem that the invention aims to solve

[0017] The purpose of the present invention is to overcome the above-mentioned technical limitations and provide a high-performance / multifunctional composite-based plate reinforcement integrated lightweight structural material, which can not only be effectively applied to ship thin plate structures, but also can be widely used in the construction field (especially, the floor structure of buildings).

[0018] More specifically, the technical subject of the present invention is to provide an integrated lightweight structural material of a plate reinforcement material based on a composite material, which can solve the problem of thermal deformation caused by welding of traditional ship steel plate structural materials by eliminating the bonding process of the lower plate reinforcement material required in traditional ship steel plate structural materials. In addition, compared with any other structural materials such as traditional ship steel plate structural materials, it is very light in weight, can achieve lightweight structure, and can also be used in the construction field.

[0019] In addition, the present invention aims to provide an integrated lightweight structural material of a plate reinforcement material based on a composite material. The material is based on a composite material and can have an upper plate of similar thickness to that of a general ship steel plate structural material, and is similar in form and assembly method to that of a general ship steel plate structural material. The material is easy to use as a ship structure, and can be particularly used in the manufacture of ship deck structures such as special car transport ships (PCCs).

[0020] The technical issues of the present invention are not limited to the above-mentioned technical issues, and those skilled in the art will clearly understand other technical issues not mentioned from the following description.

[0021] Means used to solve problems

[0022] To achieve the above-mentioned purpose, according to one aspect of the present invention, an integrated lightweight structural material of a plate reinforcement material based on a composite material can be provided, characterized in that it includes: an upper plate made of a flat metal material; a plurality of reinforcement plates made of a metal material, including a horizontal plate formed in a horizontal direction and a vertical plate bent downward from the horizontal plate, and arranged to be separated by a predetermined interval toward the lower side of the upper plate; and a core layer made of a non-metallic material, formed in the space between the upper plate and the reinforcement plate and in the space between adjacent reinforcement plates, wherein the plurality of vertical plates are formed into a pair in a manner close to and facing each other, a pair of vertical plates and the core layer formed therebetween constitute a protrusion that acts as a plate reinforcement material, and the protrusion is formed at a certain interval in the horizontal direction and extends while maintaining a certain cross-sectional shape along the length direction.

[0023] The core layer may be formed from a non-foamed polymer.

[0024] The horizontal plate and the vertical plate constituting the reinforcing plate may be formed by bending a single plate.

[0025] The lower end of the protrusion can be bent again or a separate metal finishing component can be combined at the lower end of the protrusion, so that the lower end of the protrusion has an "L"-shaped cross-section or a "⊥"-shaped cross-section, and the vertical reinforcement portion formed from the protrusion in the vertical direction can perform the web function of the plate reinforcement material, and the vertical reinforcement portion formed from the protrusion in the horizontal direction can perform the flange function of the plate reinforcement material.

[0026] Among the plurality of reinforcing plates, except for the reinforcing plates arranged at least at the two ends along the width direction, the remaining reinforcing plates may have The cross-section may also include a lower plate, which is arranged to be spaced apart from the lower side of the reinforcing plate at a predetermined interval, and the core layer may be additionally formed between the reinforcing plate and the lower plate, and the overall structure may be made to include a ladder shape.

[0027] A high-performance thermal insulation material having a thermal conductivity of 0.02 W / mK or less may be additionally provided in the core layer.

[0028] The high-performance thermal insulation material may be a vacuum thermal insulation material (VIP, Vacuum Insulation Pane).

[0029] According to one aspect of the present invention, the integrated lightweight structural material of the plate reinforcement material based on composite materials may also include a side end finishing component to finish the ends of both sides of the upper plate and the reinforcement plate, wherein the side end finishing component can be inserted between the upper plate and the reinforcement plate, and can be pushed in a predetermined distance from the ends of the upper plate and the reinforcement plate.

[0030] When connecting adjacent lightweight structural materials, the upper plates facing each other and the lower plates facing each other can be joined by welding, and a non-foaming polymer solution can be injected and cured into the space formed between the upper plate, the lower plate and the side end finishing component to airtightly finish the connection portion.

[0031] According to one aspect of the present invention, the composite material-based plate reinforcement material integrated lightweight structural material may further include a side end finishing component to finish the ends of both sides of the upper plate and the reinforcement plate, wherein the side end finishing component may be set in a straight line shape or have a The cross-section of the upper plate is angular in shape, and one end can be inserted between the upper plate and the reinforcing plate, and the other end can protrude to the outside of the upper plate and the reinforcing plate.

[0032] When connecting the adjacent lightweight structural materials, the side end finishing parts facing each other can be joined by welding or bolts.

[0033] To achieve the above objectives, the present invention may provide a ship deck structure made of a lightweight structural material having at least one of the above characteristics.

[0034] The ship may be a Pure Car Carrier (PCC).

[0035] In addition, to achieve the above-mentioned purpose, according to another aspect of the present invention, a method for manufacturing an integrated lightweight structural material of a plate reinforcement material based on a composite material can be provided, characterized in that the lightweight structural material includes: an upper plate made of a flat metal material; a plurality of reinforcement plates made of a metal material, which are arranged to be spaced apart at predetermined intervals toward the lower side of the upper plate, and include a horizontal plate formed in a horizontal direction and a vertical plate bent downward from the horizontal plate; and a core layer formed in the space between the upper plate and the reinforcement plate and in the space between adjacent reinforcement plates, and the method includes the following steps: filling the space between the upper plate and the reinforcement plate and in the space between adjacent reinforcement plates with a non-foaming polymer stock solution; curing the non-foaming polymer stock solution; and the non-foaming polymer stock solution is cured to complete the formation of the core layer.

[0036] In the above-mentioned step of filling with non-foaming polymer stock solution, a space can be formed on the upper plate and the non-foaming polymer stock solution can be poured in. Thereafter, the reinforcement plate can be inserted from above in an inverted state and pressurized to a position at a predetermined distance from the upper plate, so that the non-foaming polymer stock solution can overcome the friction resistance caused by viscosity under the pressure of the reinforcement plate and can be dissolved into the space between the reinforcement plates and filled evenly.

[0037] The amount of the non-foamed polymer solution initially poured into the space on the upper plate may be at least 2% more than the actual volume occupied by the core layer, and the excess amount may be pushed outward and discharged by the pressure of the reinforcing plate.

[0038] In the above-mentioned step of filling the non-foaming polymer solution, the space where the core layer is to be formed can be sealed, the non-foaming polymer solution can be injected into the sealed space using an injection tube, and the injection tube can be divided into multiple small tubes and arranged in the sealed space.

[0039] In the above-mentioned step of filling the non-foaming polymer solution, the space to be formed into the core layer can be sealed, an injection tube can be inserted into one side of the sealed space and the non-foaming polymer solution can be injected, and the air in the sealed space can be sucked in on the other side by a vacuum pump.

[0040] In at least one of the above-mentioned steps of filling the non-foaming polymer solution and the above-mentioned steps of curing the non-foaming polymer solution, a magnet can be set on the surface of at least one of the upper plate and the reinforcement plate or adsorbed with a vacuum adsorption device to apply tension to maintain flatness and maintain an accurate angle.

[0041] Effects of the Invention

[0042] The integrated lightweight structural material of the plate reinforcement material based on composite materials according to the present invention can be effectively applied to the thin plate structure of ships, and can also be generally applied to the construction field (especially, building floor structure), and specifically has the following effects.

[0043] (1) Since the bonding process of the lower plate reinforcement material required in the traditional ship steel plate structural material is omitted, the thermal deformation problem caused by welding of the traditional ship steel plate structural material can be fundamentally solved.

[0044] (2) The composite material-based plate reinforcement integrated lightweight structural material according to the present invention is very light in weight compared to any other structural material such as conventional ship steel plate structural materials, and can achieve lightweight structure. That is, when used as a ship or building structure, it has the effect of reducing the overall weight of the structure.

[0045] (3) The composite material-based plate reinforcement integrated lightweight structural material according to the present invention is based on composite materials and can be manufactured to a thickness similar to that of general ship steel plate structural materials, and because it is similar in form and assembly method to general ship steel plate structural materials, it can be conveniently used in the manufacture of ship structures. Preferably, the composite material-based plate reinforcement integrated lightweight structural material according to the present invention can be used as a ship deck structure, and in particular, its usefulness is expected to be outstanding when used to manufacture a deck structure of a car carrier (PCC) for which ship lightweighting is the most important requirement.

[0046] (4) The integrated lightweight structural material of the plate reinforcement material based on composite materials according to the present invention can be made into a structure with significantly thinner thickness among the structural materials based on composite materials, and has a low production cost compared to the general steel plate structural materials used in existing ships, so it also has an advantage in terms of cost.

[0047] (5) The composite material-based plate reinforcement material integrated lightweight structural material according to the present invention is made of a composite material of metal and polymer, so it can basically reduce noise and vibration, and also has heat insulation performance, so it can be used not only in the field of ships but also in building structural materials. In addition, when applied to the field of construction, a multifunctional structure can be realized by overlapping the lightweight structural materials according to the present invention and adding cold / warm and fire-resistant functions to the space between them.

[0048] The effects of the present invention are not limited to the above-mentioned effects, and other effects not mentioned will be clearly understood by those skilled in the art from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 This is a diagram showing steel plate structural materials mainly used in conventional ships.

[0050] Figures 2 to 6 1 and 2 are diagrams showing first to fifth embodiments of the lightweight structural material according to the present invention.

[0051] Figures 7 to 9 2 is a diagram showing first to third side end finishes and connection structures of a lightweight structural material according to the present invention.

[0052] Fig.10 and Fig.11 2 is a diagram showing first and second lower end finish structures of a lightweight structural material according to the present invention.

[0053] Figures 12 to 16 It is a figure for demonstrating the 1st to 5th manufacturing process of the lightweight structural material according to this invention.

[0054] Fig.17 is a diagram showing a structure in which a high-performance thermal insulation material is contained in a core layer of a lightweight structural material according to the present invention.

[0055] Fig.18 2 is a diagram showing an embodiment in which the lightweight structural material according to the present invention is applied to a floor structure of a building.

[0056] Figures 19 to 22 2 is a diagram showing first to fourth wall connection structures of a lightweight structural material according to the present invention.

[0057] Fig.23: is a diagram showing a structure of overlapping placement of a lightweight structural material according to the present invention.

[0058] Fig.24 and Fig.25 The diagrams show first and second application examples of stacked structures in which the lightweight structural material according to the present invention is stacked. DETAILED DESCRIPTION

[0059] Detailed information on the purpose and technical composition of the present invention and its operation and effects will be more clearly understood through the detailed description based on the drawings attached to the specification of the present invention.

[0060] The terms used in this specification are only used to describe specific embodiments and are not intended to limit the present invention. For example, terms such as "consisting of" or "comprising" used in this specification do not have to be interpreted as including all the various components or steps described in the present invention. It should be understood that it may not include certain components or steps, or may include additional components or steps. In addition, singular expressions used in this specification include plural expressions unless the context clearly indicates otherwise.

[0061] Hereinafter, the present invention will be described in detail by illustrating preferred embodiments of the present invention with reference to the accompanying drawings. The embodiments described below are intended to enable those skilled in the art to easily understand the technical concept of the present invention, and should not be understood as limiting the present invention. It goes without saying that the embodiments of the present invention can have various applications for those skilled in the art.

[0062] Ⅰ. Structure of lightweight structural materials

[0063] The lightweight structural material 100 according to the present invention is characterized in that it basically includes an upper plate 110 made of metal, a reinforcement plate 120 made of metal and a core layer 140 made of non-metal formed therebetween, and can be composed of a composite material of metal and non-metal, and the protruding structure formed by the lower curved structure of the reinforcement plate 120 and the core layer 140 formed therebetween in a vertical direction has the function of a plate reinforcement material.

[0064] The lightweight structural material 100 according to the present invention can have various embodiments according to the shape or manufacturing process of the lower protrusion. Figures 2 to 6 , and the possible implementation modes of the lightweight structural material 100 according to the present invention will be reviewed one by one.

[0065] (1) First Embodiment

[0066] Reference Figure 2 , starting from the first embodiment which is the most basic form of the lightweight structural material 100 according to the invention. Figure 2According to the first embodiment of the present invention, the lightweight structural material 100 may include an upper plate 110 made of a flat metal material; a reinforcing plate 120 made of a metal material, which is arranged to be spaced apart from the lower side of the upper plate 110 by a certain interval and includes a structure bent downward to perform the function of a plate reinforcing material; and a core layer 140 made of a non-metallic material formed in the space between the upper plate 110 and the reinforcing plate 120 and in the space between adjacent reinforcing plates 120.

[0067] The upper plate 110 may be provided in the form of a square plate having a predetermined thickness.

[0068] The reinforcing plate 120 may be formed by bending a plate having a predetermined thickness once or twice, and may form a downwardly bent structure by bending a portion of the plate formed in a horizontal direction in a vertical direction.

[0069] The reinforcement plate 120 may be manufactured separately into a plurality of components. The reinforcement plate 120 may include The first reinforcing plate 120a having a cross-section of The second reinforcing plate 120b of the cross-section of the light structure material 100 may be provided with a first reinforcing plate 120a at both ends in the width direction, and at least one or more second reinforcing plates 120b may be repeatedly provided therebetween. The adjacent first reinforcing plates 120a and second reinforcing plates 120b are provided so that the legs provided in the vertical direction face each other at a predetermined interval.

[0070] The core layer 140 may be formed in the space formed between the upper plate 110 and the reinforcing plate 120, and in the space between adjacent reinforcing plates 120. The core layer 140 may be formed of a non-foaming polymer, more preferably, of non-foaming polyurethane having suitable elasticity and structural strength, and as described later, the core layer 140 may be formed by solidifying a non-foaming polymer stock solution filled in the space.

[0071] The finished lightweight structural material 100 includes a flat plate portion formed in the horizontal direction and a protrusion protruding downward from the lower side of the flat plate portion, and may have a structure in which two or more protrusions are repeatedly formed at a certain interval. Here, the flat plate portion plays the role of a structural component that mainly contacts the design load when the lightweight structural material 100 is used to form a floor structure such as a deck, and the protrusion plays the role of a plate reinforcement material that improves structural performance and prevents buckling by increasing the strength and rigidity of the flat plate portion formed in the horizontal direction.

[0072] More specifically, in the lightweight structural material 100, the protrusion may be composed of the legs of the reinforcing plate 120 disposed facing each other and the core layer 140 filling the space therebetween, and the protrusion structure may perform a web function of the plate reinforcing material.

[0073] At the same time, when the reinforcing plate 120 is configured as or The metal plate constituting the reinforcing plate 120 is preferably bent by bending. This is to make the flat plate portion formed in the horizontal direction and the protruding portion formed in the vertical direction in the lightweight structural material 100 have a continuous shape without breaking, thereby achieving a structurally strong structure without the risk of welding thermal deformation or cracks.

[0074] (2) Second Embodiment

[0075] Figure 3 The second embodiment of the lightweight structural material 100 according to the present invention is shown in FIG. 1 , and its finished structure is the same as the first embodiment described above. However, the second embodiment differs from the first embodiment in that the plurality of reinforcing plates 120 are made to have a substantially The adjacent reinforcing plates 120 have the same shape of the cross-section and are connected by laser welding.

[0076] At this time, since the reinforcing plate 120 is configured such that the portion protruding downward includes a space that can be filled with the core layer 140 , a total of four bending processes are performed on one reinforcing plate 120 .

[0077] Compared with the first embodiment, the second embodiment has the inconvenience of requiring the reinforcing plate 120 to be bent more times, but its advantage is that The reinforcing plate 120 manufactured in this form already includes a protruding structure, and the lower end of the protruding structure is blocked, so the structure can be more stable, and the operation of forming the core layer 140 as described later can also be carried out more smoothly.

[0078] (3) Third Embodiment

[0079] Reference Figure 4 According to the third embodiment of the present invention, the lightweight structural material 100 may have a structure in which the lower end of the protrusion protruding downward is bent again in the horizontal direction. That is, the protrusion protruding downward from the lightweight structural material 100 has a substantially Shaped cross section.

[0080] Therefore, in the third embodiment, the protrusion protruding below the lightweight structural material 100 may include a vertical reinforcement portion formed along the vertical direction and a horizontal reinforcement portion formed along the horizontal direction, and the vertical reinforcement portion can perform the web function of the plate reinforcement material, and the horizontal reinforcement portion can perform the flange function of the plate reinforcement material.

[0081] at the same time, Figure 4The structure is shown in which the end of the horizontal reinforcement portion formed at the lower end of the protrusion is completed with the core layer 140 exposed, but similar to the aforementioned second embodiment, this portion can also be constructed with a structure blocked by the reinforcement plate 120.

[0082] (4) Fourth Embodiment

[0083] Reference Figure 5 According to the fourth embodiment of the present invention, the lightweight structural material 100 may be composed of a structure in which the lower end of the protrusion protruding downward extends to both sides in the horizontal direction and has a substantially “⊥” shaped cross section.

[0084] In the fourth embodiment, the protrusion protruding downward of the lightweight structural material 100 may include a vertical reinforcement portion formed along the vertical direction and a horizontal reinforcement portion formed along the horizontal direction, and the vertical reinforcement portion may perform the web function of the plate reinforcement material, and the horizontal reinforcement portion may perform the flange function of the plate reinforcement material, similar to the aforementioned third embodiment.

[0085] According to the lightweight structural material 100 of the third and fourth embodiments, as the shape of the protrusion increases toward the lower end, the section modulus is greatly increased, and thus the function of a more effective plate reinforcing material can be performed.

[0086] (5) Fifth Embodiment

[0087] Reference Figure 6 As another embodiment, a fifth embodiment of the lightweight structural material 100 according to the present invention may include an upper plate 110 made of a flat metal material; a lower plate 130 made of a flat metal material arranged side by side with the upper plate 110 at a position separated from the lower side of the upper plate 110 by a certain interval; a plurality of reinforcing plates 120 arranged between the upper plate 110 and the lower plate 130; and a core layer 140 made of a non-metallic material formed in the space between the lower plates 130 and the space between adjacent reinforcing plates 120, which may be roughly composed of a ladder-like shape.

[0088] The reinforcing plate 120 may be disposed to be spaced apart from the upper plate 110 at a certain interval to form a space therebetween, and similarly, may also be disposed to be spaced apart from the lower plate 130 at a certain interval.

[0089] In the fifth embodiment, the reinforcing plate 120 may include The first reinforcing plate 120c having a cross-section of The second reinforcing plate 120d with a shaped cross-section may be provided with a first reinforcing plate 120c at both ends along the width direction of the lightweight structural material 100, and at least one second reinforcing plate 120d may be repeatedly provided therebetween. The spacing between the first reinforcing plate 120c and the second reinforcing plate 120d and between adjacent second reinforcing plates 120d may be formed to be the same.

[0090] The core layer 140 may be formed in the space between the upper plate 110 , the reinforcing plate 120 , and the lower plate 130 and in the space between adjacent reinforcing plates 120 , so that the reinforcing plates 120 are in a form surrounded by the core layer 140 .

[0091] In the lightweight structural material according to the fifth embodiment of the present invention, the portion formed along the vertical direction of the reinforcement plate 120 and the core layer 140 can perform the web function of the plate reinforcement material, and the structure of the core layer 140 formed along the horizontal direction between the reinforcement plate 120 and the lower plate 130 and the lower plate 130 attached to its lower end can perform the flange function of the plate reinforcement material.

[0092] The protrusion protruding downward from the lightweight structural material 100 of the present invention including the first to fifth embodiments described above (in the fifth embodiment, the vertical columnar portion formed by the reinforcing plates 120 facing each other and the core layer 140 formed therebetween can be regarded as the protrusion) plays a role in increasing the overall section modulus of the structure. The above section modulus can be determined by the height or shape of the protrusion as a plate reinforcement structure.

[0093] Traditional steel plate structural materials (refer to Figure 1 ) is only composed of metals mainly suitable for ship structures. In order to strengthen the structure, the plate reinforcement material 20 is combined together by welding on the lower side of the upper plate 10. As mentioned in the background technology, this traditional method has considerable thermal deformation problems when connecting the plate reinforcement material 20 by welding.

[0094] However, unlike the traditional iron plate structural material in which the upper plate 10 and the plate reinforcement material 20 as structural members are separately manufactured and then joined together by welding, the lightweight structural material 100 according to the present invention is integrally manufactured from a flat plate portion and a protruding portion protruding therefrom, so as to be configured in a form that self-contains the plate reinforcement structure. Therefore, there is no need to worry about the same welding thermal deformation problem as the traditional one.

[0095] In addition, even if it is assumed that the upper plate 10 and the plate reinforcement material 20 are connected by bolts without welding when manufacturing traditional steel plate structural materials, additional hole construction or local structural reinforcement work is required for the bolt connection between the upper plate 10 and the plate reinforcement material 20. On the contrary, the lightweight structural material 100 according to the present invention, which is formed integrally by the plate reinforcement structure, does not require the above-mentioned additional works at all, and therefore has stable performance in structure.

[0096] In addition, the lightweight structural material 100 according to the present invention already includes a plate reinforcement structure through a protrusion, so compared with the case where the plate reinforcement structure needs to be welded together, the thickness of the upper plate 110 and the reinforcement plate 120 can be formed into a thinner structure, thereby producing an optimized composite structure.

[0097] In particular, the lightweight structural material 100 according to the present invention is characterized in that not only the flat plate portion but also the protrusion having the function of a plate reinforcing material is not composed of a single metal material but is composed of a composite material (metal + polymer). According to the structure of the present invention, its advantage is that compared with the case of using a plate reinforcing material composed only of metal, a structural lightweight of about 40% to 50% can be achieved.

[0098] The thickness of the upper plate 110, the reinforcement plate 120, the lower plate 130 and the core layer 140 constituting the inner core constituting the lightweight structural material 100 according to the present invention can be designed so that the lightweight structural material 100 according to the present invention can achieve a structural performance equivalent to the structural strength of general ship steel plate structural materials.

[0099] Specifically, the thickness of the upper plate 110 and the reinforcing plate 120 of the lightweight structural material 100 according to the present invention can be formed to be 0.4 to 20 mm, respectively. At this time, as described later, when the lightweight structural material 100 according to the present invention is connected between individual modules or to any other structure, welding work may be required, so the thickness of the upper plate 110 and the reinforcing plate 120 constituting the outer plate of the lightweight structural material 100 is preferably formed to be 0.4 mm or more for laser welding. In addition, in order to achieve the lightweight structure of the present invention as a technical subject, the thickness of the upper plate 110 and the reinforcing plate 120 is preferably formed to be 10 mm or less, so the present invention proposes 0.4 to 10 mm as a more preferred thickness of the metal plate constituting the upper plate 110 and the reinforcing plate 120. As shown in the fifth embodiment, if the lower plate 130 is also included, the thickness of the lower plate 130 follows the thickness of the upper plate 110.

[0100] The thickness of the core layer 140 of the lightweight structural material 100 according to the present invention can be configured to vary between 3 and 40 mm. At this time, the core layer 140 can also be formed so that the thickness of the portion formed in the horizontal direction and the portion formed in the vertical direction (the portion formed between the reinforcement plates 120 facing each other) are different.

[0101] That is, in the lightweight structural material 100 according to the present invention, the thickness of the core layer 140 of the flat plate portion and the thickness of the core layer 140 of the protruding portion can be formed to be the same, but can also be adjusted differently. If different thicknesses are to be formed, it is preferred that the thickness of the core layer 140 of the protruding portion serving as a plate reinforcement material is formed to be thinner than the thickness of the core layer 140 of the flat plate portion.

[0102] At the same time, one thing that should not be confused by the names of the above components is that the upper plate 110 of the lightweight structural material 100 according to the present invention does not have to have structural properties equivalent to those of the upper plate 10 of a general ship steel plate structural material alone, but it should be understood that in the lightweight structural material 100 according to the present invention, including the upper plate 110, the reinforcement plate 120 and the core layer 140 formed therebetween, the flat plate portion formed in the horizontal direction and in direct contact with the design load can be designed to have structural properties equivalent to those of the upper plate 10 of a general ship steel plate structural material. The same is true when determining the thickness of the reinforcement plate 120 and the core layer 140 formed therebetween that constitute the plate reinforcement structure.

[0103] That is, in the lightweight structural material 100 according to the present invention, the entire flat plate portion including the upper plate 110, the reinforcing plate 120 and the core layer 140 formed therebetween should correspond to the upper plate 10 of the general ship steel plate structural material in order to consider the structural strength, and therefore, in the lightweight structural material 100 according to the present invention designed to have structural performance equivalent to that of the general ship steel plate structural material, the thickness of the upper plate 110 will be much thinner than the upper plate 10 of the general ship steel plate structural material corresponding thereto. For example, the composite structure of the lightweight structural material 100 according to the present invention, which is equivalent to the 6mm upper plate 10 of the general ship steel plate structural material, can be formed into a 1mm thick upper plate 110, a 5mm thick core layer 140 and a 1mm thick reinforcing plate 120.

[0104] In addition, in the lightweight structural material 100 according to the present invention, the spacing d between the protruding structures that perform the web and / or flange structural functions of the plate reinforcement material can be formed in the range of 200 to 3000 mm. More preferably, the spacing d between the protruding parts of the lightweight structural material 100 according to the present invention can be similar to the spacing of general ship steel plate structural materials, and is roughly formed to be 600 to 900 mm. If the thin thickness of the lightweight structural material 100 is abandoned (for example, as described later, due to the placement of a high-performance thermal insulation material 141 inside the core layer 140, the thickness is increased), the spacing d between the protruding structures can be increased to 1500 to 3000 mm.

[0105] The width of the lightweight structural material 100 according to the present invention can be changed according to the number of protrusions formed. For example, when the spacing between the protrusions is uniformly 700 mm, if the structure has 3 to 4 protrusions, the entire width of the board can be formed to be approximately 2100 to 3500 mm.

[0106] The height h of the protrusion protruding downward from the light structural material 100 can be formed to a level having equivalent structural performance to that of a general ship steel plate structural material, compared to the section modulus of the entire structure, and similar to or lower than the existing plate reinforcement material made only of metal. For example, if the height of the plate reinforcement material of the existing steel plate structural material to achieve equivalent performance is 100 mm, the height h of the protrusion of the light structural material 100 according to the present invention can also be formed to a level similar to this. However, as mentioned above, when the shape of the protrusion is added from the "l" shape having a simple straight line shape to the "L" shape, "⊥" shape and trapezoidal shape, the section modulus of the entire structure increases, so the height h of the protrusion may be lower. Among them, the height h of the protrusion can represent the height from the lowermost end of the reinforcement plate 120 to the bottom of the reinforcement plate 120 constituting the flat plate portion formed in the horizontal direction.

[0107] In addition, as in the third and fourth embodiments (see Figure 4 and Figure 5 ), if the lightweight structural material 100 according to the present invention is constructed to also include a horizontal reinforcement portion formed in a horizontal direction at the lower end of the protrusion, the width w of the horizontal reinforcement portion can also be formed to an equivalent size similar to that of the existing steel plate structural material as in the aforementioned concept.

[0108] When the thickness, width, height, etc. of each component are designed according to the range suggested above, the lightweight structural material 100 according to the present invention can be made into a long-span structure ranging from a length of about 3m to a maximum length of 14m. As such, the reason why the lightweight structural material 100 according to the present invention can be made into a long-span structure of up to 14m is that the core layer 140 composed of a non-foamed polymer is firmly bonded between the upper plate 110 and the reinforcement plate 120, so that it has basic structural properties, wherein the non-foamed polymer has a specific gravity of 0.8 to 1.8 and is very light compared to metal. At the same time, it is also because the protrusion protruding downward from the lightweight structural material 100 plays the role of a plate reinforcement material.

[0109] In addition, it is worth noting that the lightweight structural material 100 according to the present invention, which is made into a large-span structure, can also exert structural performance equal to or better than that of general ship steel plate structural materials or building reinforced concrete even without adding other reinforcement materials in the direction across the width of the structural material. That is, Figure 1The general ship steel plate structural material shown should be constructed to include plate reinforcement material 20 to reinforce the longitudinal structure of the longitudinal girder (Longitudinal girder) 21 and the transverse frame (Transverse frame) 22 to reinforce the transverse structure, but the lightweight structural material 100 according to the present invention only needs to form multiple protrusions at the lower part of the plate structure along the length direction, and there is no need to set a separate reinforcement structure along the width direction across it.

[0110] The lightweight structural material 100 according to the present invention can be made to meet a predetermined deflection standard, and this deflection standard, as described above, can be met by adjusting / selecting the height and shape of the protrusion that functions as a plate reinforcement material so that the cross-sectional modulus of the entire structure is formed to be above a predetermined level.

[0111] For example, the total length of the lightweight structural material 100 according to the present invention is 6 m, the thickness of the upper plate 110 and the reinforcing plate 120 are respectively formed to be 1 mm, and the core layer 140 is formed of a 5 mm thin core. 2 Under the conditions of fixing both ends, the spacing between the protrusions is formed to be 600mm. If the L / 480 deflection standard is to be met, the height h of the protrusion can be calculated to be approximately 125mm when it is in an "l" shape, approximately 100mm when it is in a "⊥" shape forming a horizontal reinforcement plate with a width w of 100mm, and approximately 65mm when it is a trapezoid.

[0112] In the above deflection standard, "L" refers to the length (span) of the lightweight structural material 100. To meet the L / 480 deflection standard, the central portion of the lightweight structural material 100 should not sag more than 1 / 480 of the total length of the lightweight structural material 100. As described above, when the lightweight structural material 100 according to the present invention is manufactured to a length (span) of 6m and both ends are fixed, the maximum deflection is 6000 / 480=12.5 (mm) or less to meet the L / 480 deflection standard.

[0113] That is, in order to meet the deflection standard, the structural performance of the lightweight structural material 100 can be achieved by adjusting the height or shape of the protrusion, etc. In addition, by providing a bonding strength above a certain level between the upper plate 110, the reinforcement plate 120 and the core layer 140, the structural performance of the lightweight structural material 100 can be further helped to be achieved.

[0114] Specifically, the non-foamed polymer constituting the core layer 140 has its own adhesive force. As described later, during the solidification process of the liquid non-foamed polymer stock solution, the surfaces in contact with the upper plate 110 and the reinforcing plate 120 will be airtightly bonded together. The present invention can impart an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, between the upper plate 110 and the core layer 140 and between the reinforcing plate 120 and the core layer 140. As in the fifth embodiment, if the lower plate 130 is also included, the same adhesive strength can also be imparted between the lower plate 130 and the core layer 140.

[0115] As described later, according to the lightweight structural material 100 of the present invention, the side end or the lower end can be finished with a non-metallic or metallic finishing component for the purpose of future structural combination with other modules or structural strength optimization or fatigue strength reinforcement required by the module itself. Even in this case, it is preferred to provide a bonding strength of at least 1 MPa (more preferably 6 MPa or more) between the non-foamed polymer serving as the inner core and the finishing component.

[0116] As described above, the lightweight structural material 100 according to the present invention has the material characteristics of a composite material composed of a metal upper plate 110 and a reinforcement plate 120 and a core layer 140 composed of a non-foamed polymer, and the plate reinforcement structure itself can achieve ultra-light and significant structural performance.

[0117] Specifically, the lightweight structural material 100 made of the composite material of the present invention can achieve equivalent structural performance with about 50% to 60% of the weight compared with the general steel plate structural material mainly used in the shipbuilding field, and can achieve equivalent structural performance with about 15% to 25% of the weight compared with the reinforced concrete mainly used in the construction field.

[0118] In addition, according to the general standard carbon emission table, it is known that steel plates and non-foamed polymers will produce 2 to 3 kg of CO2 per kilogram (kg). However, the specific gravity of non-foamed polymers is between 0.8 and 1.8, which is much lower than the specific gravity of steel plates (7.85), so the carbon emissions generated during the structure production process will be greatly reduced, which may be reduced by about 50% compared with the past.

[0119] Ⅱ. Finishing and connection structure of lightweight structural materials

[0120] The following references Figures 7 to 11 , the finishing and connection structure of the lightweight structural material 100 according to the present invention is checked.

[0121] (1) First side end finishing and connection structure

[0122] First, refer to Figure 7In the lightweight structural material 100 according to the present invention, a first side end finishing member 151 made of a metal or non-metal material may be inserted and arranged between the upper plate 110 and the reinforcing plate 120 at both ends formed in the horizontal direction. Here, when the first side end finishing member 151 is made of a non-metal material, it is preferably made of a material that can generate a bonding strength of at least 1 MPa (more preferably 6 MPa or more) with the non-foamed polymer as the inner core.

[0123] Moreover, adjacent light-weight structural materials 100 can be joined together by laser welding between the upper plates 110 and the reinforcing plates 120 that are placed in contact with each other. As mentioned above, laser welding has the advantage of small thermal deformation, but due to the problem that the thicker the thickness, the lower the efficiency, it is difficult to be applied to general steel plate structural materials of ships with a thickness of more than 6 mm. However, the present invention uses metal plates thinner than 6 mm (for example, 0.5 to 5 mm) as the upper plate 110 and the reinforcing plate 120, so it has a favorable advantage in the application of laser welding.

[0124] In addition, in this embodiment, the first side end finishing component 151 can be pushed into the inside of the lightweight structural material 100 at a predetermined distance and placed. Accordingly, when adjacent lightweight structural materials 100 are placed in contact with each other to connect two or more lightweight structural materials 100, a space S can be formed between the first side end finishing components 151 facing each other and arranged on each lightweight structural material 100. By injecting a non-foaming polymer stock solution (more preferably a non-foaming polyurethane stock solution) into the space S and curing it, the connection parts of the adjacent lightweight structural materials 100 can be airtightly finished. At this time, the self-adhesive force of the non-foaming polymer can be used to give additional bonding force between the lightweight structural materials 100, thereby achieving an additional effect.

[0125] At the same time, the first side end finishing member 151 may be deleted, and the non-foamed polymer as the core layer 130 may be exposed. However, in this case, a predetermined space S may be formed at the portion where the lightweight structural material 100 is connected, and the non-foamed polymer stock solution may be injected into the space S to achieve airtight finishing in the same manner.

[0126] (2) Second side end finishing and connection structure

[0127] Secondly, refer to Figure 8 In the lightweight structural material 100 according to the present invention, the two ends formed in the horizontal direction may be inserted into and provided with the second side end finishing parts 152 made of metal material.

[0128] In this embodiment, the second side end finishing component 152 can be made of a metal plate with a sub-shape in cross-section and a thickness corresponding to the core layer 140, one end of which can be inserted into the interior of the lightweight structural material 100, and the other end can protrude to the outside of the lightweight structural material 100 and be exposed.

[0129] The second side end finishing part 152 protruding outward can be structurally combined with the second side end finishing part 152 provided on the side of the adjacent other lightweight structural material 100 by welding or bolts. As shown in this embodiment, when the side end of the lightweight structural material 100 is finished by a metal material with a predetermined thickness, common welding such as CO2 welding can be applied, and in addition to welding, mechanical combining methods such as bolts can also be applied, so it has the advantage of excellent design flexibility.

[0130] (3) Third side end finishing and connection structure

[0131] Reference Fig. 9 In the lightweight structural material 100 according to the present invention, the two ends formed in the horizontal direction may be inserted into and provided with a third side end finishing member 153 made of a metal material.

[0132] The third side end finishing and connection structure of the lightweight structural material 100 according to the present invention is similar to the second side end finishing and connection structure described above. However, unlike the second side end finishing component 152 which is set in a simple straight line shape, the third side end finishing component 153 is different in that it is set to have The angular shape of the cross-section.

[0133] According to this embodiment, when it is necessary to connect two or more lightweight structural materials 100 that are terminated with the third side end termination components 153, the third side end termination components 153 disposed on adjacent lightweight structural materials can be structurally connected by welding or bolts (welding and bolts can also be used simultaneously). As shown in this embodiment, when the cross-section of the third side end termination component 153 is If it is a shape, there are legs, so it can also be regarded as a structure that is more easily suitable for bolt connection.

[0134] (4) Lower end finishing structure

[0135] Meanwhile, for structural efficiency, in the lightweight structural material 100 according to the present invention, the lower end of the protrusion performing the function of the plate reinforcing material may be reinforced by finishing with a metal structure.

[0136] More specifically, Fig.10 The first lower end finishing member 154 having an "L" shaped cross section as shown in Fig.11The second lower end finishing member 155 having a “⊥” shaped cross section shown in FIG. is inserted into and coupled to the lower end of the protrusion. However, Figure 3 In the second embodiment shown, when the lower end of the protruding portion of the lightweight structural material 100 according to the present invention is manufactured in a closed state, the above-mentioned lower end finishing structure does not need to be applied.

[0137] In addition, in the protrusion of the lightweight structural material 100 according to the present invention, even if the end of the vertical structure (vertical reinforcement part) having the web function of the plate reinforcement material or the end of the horizontal structure (horizontal reinforcement part) having the flange function is not terminated with metal, the cross-sectional moment change of the structure is almost the same, so it has little effect on the overall structural performance. In other words, in terms of optimization of structural performance, whether the end of the protrusion is terminated with metal or not terminated and the non-foamed polymer as the core is directly exposed, there is not much difference, so whether the above-mentioned side end or lower end termination structure is applicable can be determined by considering whether there is a connection or other special purpose between the modules of adjacent lightweight structural materials 100.

[0138] The finishing structure of the lightweight structural material 100 according to the present invention not only has the function of assisting the combination and connection between two or more lightweight structural materials 100, but also can have additional functions such as closing the space between the upper plate 110 and the reinforcement plate 120 during the manufacturing process of the lightweight structural material 100.

[0139] In addition, the above-mentioned finishing parts 151 / 152 / 153 / 154 / 155 can be inserted between the upper plate 110 and the reinforcing plate 120, and the contact surface thereof can be bonded with an adhesive, and the surface in contact with the core layer 140 can also be bonded by the self-adhesive force of the non-foamed polymer forming the core layer 140. Even when the finishing parts 151 / 152 / 153 / 154 / 155 are made of metal, welding is not required, and sufficient strength can be obtained by simply inserting and bonding. However, in order to prevent the peeling phenomenon of the bonding surface, the upper plate 110 and the reinforcing plate 120 and the finishing parts 151 / 152 / 153 / 154 / 155 can be given a bonding strength of 1 to 10 MPa, more preferably 6 MPa, as described above.

[0140] In the lightweight structural material 100 according to the present invention, the upper plate 110 and the reinforcing plate 120 are formed to be very thin, so that thermal deformation can be minimized by the application of laser welding. In particular, since the core layer 140 is formed by filling a non-foamed polymer and then curing, laser welding can also be performed after the structure is firm, thereby minimizing welding deformation.

[0141] In addition, in the lightweight structural material 100 according to the present invention, the reinforcement plate 120 of the metal material constituting the protrusion is bonded to the internal core layer 140 with a bonding strength of more than 1 MPa, more preferably more than 6 MPa, so that the function of the integrated plate reinforcement material can be achieved without separate welding or with only minimal tag welding.

[0142] III. Manufacturing process of lightweight structural materials

[0143] Next, refer to Figures 12 to 16 , the specific manufacturing process of the lightweight structural material 100 according to the present invention is reviewed.

[0144] Generally, the plate reinforcement material used in ships has a thickness of 6 to 30 mm, but a thin thickness of about 6 to 15 mm is usually used. If it is replaced with the composite material structure of the non-foamed polymer and metal proposed in the present invention, a metal sheet with a thickness of 1 to 3 mm can be used as the upper plate 110 and the reinforcement plate 120, and the thickness of the non-foamed polymer constituting the core layer 140 can be formed into an ultra-thin structure of about 5 to 15 mm.

[0145] However, it is not easy to form a non-foamed polymer structure with such a thin thickness in reality. Because the non-foamed polymer stock solution has a viscosity higher than that of lubricating oil before solidification, if the space to be filled is too narrow, injection will be difficult due to friction resistance, and it will be difficult to spread evenly in the space. Considering the manufacturing characteristics of composite materials composed of metal and non-foamed polymer, some classification rules that stipulate the basic performance and structural requirements of ships recommend that the thickness of the metal plate be formed to be 3 mm or more and the thickness of the core material composed of non-foamed polymer be formed to be 15 mm or more. If not complied with, it shall be approved separately.

[0146] The manufacturing process described below relates to the case where the core layer 140 of the lightweight structural material 100 is formed by a non-foamed polymer (for example, non-foamed polyurethane), and is proposed in particular to overcome the above-mentioned manufacturing difficulties, that is, to solve the problem that the core layer 140 composed of a non-foamed polymer is difficult to form a thin thickness, and more preferably, a method is proposed in which even if the core layer 140 is formed to a thickness of less than 15 mm, non-foamed polymer can be uniformly filled in its space to obtain a uniform core layer 140.

[0147] (1) First Manufacturing Process

[0148] like Fig.12As shown, the first manufacturing process of the lightweight structural material 100 according to the present invention is to pour the non-foaming polymer stock solution on the reinforcing plate 120, fill and cover the upper plate 110. If the lower end of the reinforcing plate 120 is opened, the lower end can be formed into a closed structure by using a temporary dam, or a temporary dam can be applied to the side of the reinforcing plate so that the space above the reinforcing plate 120 can be filled with a predetermined liquid level of the non-foaming polymer stock solution. If the lower end of the reinforcing plate 120 is formed into a blocked structure or is terminated with a separate finishing component, it is not necessary to apply a temporary dam, which is also the case in other manufacturing processes described later.

[0149] At the same time, the manufacturing process is not a method of injecting the non-foaming polymer stock solution into a closed space, but pouring it into an open space for filling. As the operation is performed in an open cavity, the contact between the non-foaming polymer stock solution and the air will form bubbles. If the bubbles are not removed and remain inside the core layer 140, the structural performance may be affected, so an additional process is required to remove the bubbles.

[0150] To this end, the manufacturing process fills the reinforcement plate 120 with a non-foaming polymer stock solution that is at least 2% more than the amount corresponding to the actual volume occupied by the core layer 140, and when covering the upper plate 110, the entire plate is not covered at once, but is slightly tilted or bent to push the surface of the non-foaming polymer stock solution to cover. That is, the upper plate 110 can be used to push the surface of the non-foaming polymer stock solution from one side to the other side to cover, and the excess non-foaming polymer stock solution is pushed out of the panel, and bubbles can be removed through this process. If the lower end of the reinforcement plate 120 forms a blocked structure, a separate hole can also be formed for the overflow of the non-foaming polymer stock solution and the air valve (vent).

[0151] (2) Second Manufacturing Process

[0152] Reference Fig.13 The process of the second manufacturing process of the lightweight structural material 100 according to the present invention is described.

[0153] First, when the upper plate 110 is turned over, a temporary dam is set at the edge of the upper plate 110, and a liquid non-foaming polymer stock solution is injected into the space formed by the upper plate 110 and the edge portion (temporary dam). In this embodiment, the amount of the non-foaming polymer stock solution initially filled can be at least 2% more than the amount corresponding to the actual volume occupied by the core layer 140.

[0154] Then, the reinforcing plate 120 is introduced from above and pressed downward while the non-foaming polymer stock solution is poured into the space of the upper plate 110. The reinforcing plate 120 may be pressurized by a hydraulic device or the like until a predetermined interval is reached between the reinforcing plate 120 and the upper plate 110. At this time, a spacer may be placed between the upper plate 110 and the reinforcing plate 120 to maintain the interval between the upper plate 110 and the reinforcing plate 120 at a relatively thin designed thickness.

[0155] The non-foamed polymer stock solution filled in the space of the upper plate 110 can be dissolved into the vertical space (thin gap that acts as the web of the plate reinforcing material) formed between the legs of the reinforcing plates 120 facing each other by the pressure of the reinforcing plates 120. At this time, since the amount of the non-foamed polymer stock solution filled is greater than the actual volume occupied by the core layer 140, the excess amount can be pushed out and discharged, and bubbles can also be removed through this process.

[0156] The non-foamed polymer stock solution uniformly filled between the upper plate 110 and the reinforcing plate 120 hardens over time to form a core layer 140 . Due to the formation of the core layer 140 , the manufacture of the lightweight structural material 100 according to the present invention is completed.

[0157] The first and second manufacturing processes are not a method of injecting the non-foaming polymer stock solution into a closed space, but a method of pouring it into an open space for filling. The advantages of these processes are that a thin plate reinforcement structure can be formed by pressurizing to overcome the friction resistance generated when the non-foaming polymer stock solution is injected, and it is possible to visually check whether the non-foaming polymer stock solution is correctly filled into the overall structure corresponding to the core layer 140.

[0158] (3) Third Manufacturing Process

[0159] like Fig.14 As shown, the third manufacturing process of the lightweight structural material 100 according to the present invention utilizes a method of forming a closed space between the upper plate 110 and the reinforcement plate 120, and injecting a non-foaming polymer solution into the closed space, and the injection tube (injection tube) used to inject the non-foaming polymer solution is divided into multiple small tubes instead of one.

[0160] Generally, when two organic compound liquids such as ISO and polyol are mixed, the non-foaming polymer undergoes a chemical reaction and starts to solidify from then on. The chemical reaction takes only a few minutes, so the injection of the non-foaming polymer stock solution must be completed within a few minutes. In addition, since the non-foaming polymer stock solution has its own viscosity, it may be difficult to spread evenly within a few minutes.

[0161] This manufacturing process is designed to solve the above-mentioned process difficulties by dividing the injection tube for injecting the non-foaming polymer solution into a plurality of small tubes and tightly arranging them in the space where the core layer 140 is to be formed, so that the non-foaming polymer solution can be quickly and evenly injected into the enclosed space between the upper plate 110 and the reinforcement plate 120.

[0162] When this manufacturing process is applied, if there is an unblocked part between the plates, a temporary dam can be used to form a closed space, and if it is finished with a separate finishing component, the finishing component can play the role of sealing the part. This is also applicable in other manufacturing processes.

[0163] (4) Fourth Manufacturing Process

[0164] 15 , the fourth manufacturing process of the lightweight structural material 100 according to the present invention utilizes a method of forming a closed space between the upper plate 110 and the reinforcing plate 120, and injecting a non-foamed polymer solution into the closed space, and the injection is performed while removing air from the closed space using a vacuum pump VP.

[0165] More specifically, after a sealed space is formed between the upper plate 110 and the reinforcing plate 120 , an injection pipe is inserted on one side to inject the non-foaming polymer solution, while the air in the sealed space is sucked in by a vacuum pump VP on the other side.

[0166] This manufacturing process has the following advantages: due to the pressure difference inside and outside the closed space, the non-foaming polymer stock solution can be injected with a thin thickness while overcoming the friction resistance when injecting, and the suction of the vacuum pump VP can also be used for rapid injection.

[0167] (5) Fifth Manufacturing Process

[0168] The upper plate 110 and the reinforcing plate 120 used to make the lightweight structural material 100 according to the present invention use metal plates that are much thinner than iron plates used in general ships. Therefore, the engineering trouble caused by this is that it is difficult to maintain the shape of the plate and to manage its flatness before or during the filling of the core (non-foamed polymer) due to the thin thickness of the metal plate.

[0169] Conventionally, in the process of filling the core between two plates, a spacer is used to maintain the shape (or maintain the interval). In addition, when a non-foamed polymer is used as a core, it has the property of slightly expanding during the curing process, so the upper plate is squeezed by a considerable load. However, as in the present invention, when the thickness of the metal plate forming the upper plate 110 and the reinforcing plate 120 is formed to be very thin below a certain level, it is difficult to maintain the shape and flatness of the plate using the above conventional method.

[0170] In addition, due to the self-weight of the upper plate, the plate may sag. At this time, if the core is thick enough, the strength of the chemical reaction is also strong, so the sagging upper plate can be pushed back to its original position by the expansion force. However, when the core layer 140 is formed to be thin as in the present invention, the expansion force is weak and therefore insufficient to restore the state in which the upper plate 110 sags due to its own weight.

[0171] Furthermore, the lightweight structural material 100 according to the present invention includes a structure in which the reinforcing plate 120 is bent downward. In this case, due to the characteristic that the reinforcing plate 120 is composed of a thin plate, it is also very difficult to keep the bending angle constant.

[0172] The fifth manufacturing process of the lightweight structural material 100 according to the present invention is proposed to solve the difficulties in the above-mentioned processes. If the above-mentioned first to fourth manufacturing processes are processes related to filling non-foamed polymers, the fifth manufacturing process can be regarded as a process related to maintaining the overall shape and flatness of the structural material before and during the injection of non-foamed polymers.

[0173] Specifically, Fig.16 As shown, in a state where the space between the upper plate 110 and the reinforcing plate 120 is filled with a non-foaming polymer concentrate, when a magnet M is placed on the upper plate 110 disposed at the upper portion, due to the magnetic field generated by the magnet M, the upper surface of the upper plate 110 is in close contact with the magnet M, thereby maintaining a flat state.

[0174] For reference, Fig.16 In the illustrated embodiment, since the process is carried out with the reinforcement plate 120 and the upper plate 110 stacked in sequence on a surface plate, the magnet M is placed on the upper surface of the upper plate 110. If the upper plate 110 and the reinforcement plate 120 are turned over to carry out the process, the magnet M can be placed on the reinforcement plate 120 placed on the upper side based on the non-foaming polymer stock solution.

[0175] Here, the magnet M can be understood as a concept including all magnetic bodies that can generate a force to attract metal, including electromagnets. The size of the magnet M does not need to correspond to the entire area of ​​the plate to be kept flat, and even if it only occupies a part of the area, the effect of flattening the entire plate can be obtained. In addition, multiple magnets M can be placed on the plate, and when only one magnet M is used, it is preferably placed in the center of the plate.

[0176] In addition, the side surfaces of the reinforcing plate 120 not only placed in the horizontal direction but also erected in the vertical direction may also be provided with the magnets M according to the same principle to maintain the flatness and obtain the desired bending angle.

[0177] At this time, the magnet M may be configured to be included in a working jig or a platform that fixes the positions of the upper plate 110 and the reinforcing plate 120. In the accompanying drawings, only the magnet M that applies tension to the reinforcing plate 120 is shown as being included in the platform, but it goes without saying that the magnet M that applies tension to the upper plate 110 may also be included in the working jig or the platform. In this case, even if there is no separate clamping portion to fix the upper plate 110 or the reinforcing plate 120 to the working jig or the platform, the incidental effect of easily clamping the upper plate 110 and the reinforcing plate 120 made of metal plates by the pulling force of the magnet can be enjoyed.

[0178] In addition, the manufacturing process may also be implemented by using a vacuum adsorption device instead of the magnet M. Specifically, the vacuum adsorption device maintains the shape and flatness of the structural material by adsorbing a specific portion of the plate that needs to maintain flatness and applying tension.

[0179] As in the case of applying the magnet M, the vacuum adsorption device can perform the function of maintaining flatness simply by providing adsorption force to a portion of the plate, rather than the entire area. Preferably, the central portion of the plate to be maintained flat is adsorbed. In addition, multiple vacuum adsorption devices can also be applied to one plate.

[0180] The lightweight structural material 100 according to the present invention manufactured by applying the fifth manufacturing process as described above has a flat surface and can maintain the same overall thickness, thereby achieving uniform structural performance. In addition, since the flatness problem is solved during the manufacturing process, the number of spacers provided between the upper plate 110 and the reinforcing plate 120 can be greatly reduced, which has the effect of reducing manufacturing time and cost.

[0181] According to the thickness and end treatment method of the structure used to form the lightweight structural material 100 according to the present invention, two or more of the first to fifth manufacturing processes described above can be applied in parallel. For example, the vacuum pump of the fourth manufacturing process can be used to remove air from the closed space while the second manufacturing process is performed in a closed space instead of an open cavity, and, like the third manufacturing process, the vacuum pump of the fourth manufacturing process can be applied while injecting the non-foamed polymer stock solution using multiple injection pipes. The fifth manufacturing process is a process for maintaining the morphology and flatness of the structural material, and therefore can be used in parallel with any other manufacturing process.

[0182] In addition, thin non-foamed polymers have less absolute capacity for chemical reactions than thick non-foamed polymers, so curing takes longer. In particular, in low-temperature periods such as winter, the rate of chemical reactions between molecules for curing is also reduced, so curing takes longer or, in extreme cases, does not occur. To prevent this from happening, a hot wire or warm pipe device that can increase the surface temperature of the manufacturing jig can be set up, which is a common item for all manufacturing processes.

[0183] IV. Additional Examples of Lightweight Structural Materials

[0184] At the same time, when constituting the core layer 140 of the lightweight structural material 100 according to the present invention, a high-performance thermal insulation material that already has thermal insulation and structural properties can also be used additionally. In this case, since a high-performance thermal insulation material with low thermal conductivity is additionally provided between the upper plate 110 and the reinforcing plate 120, excellent performance in terms of thermal insulation can be achieved.

[0185] More specifically, if Fig.17 As shown, the core layer 140 can be formed by placing a non-foamed polymer and a high-performance thermal insulation material 141 with a thermal conductivity lower than 0.02W / mK between the upper plate 110 and the reinforcement plate 120. For example, when the core layer 140 is formed to include a vacuum insulation material (VIP, Vacuum Insulation Pane) with a thermal conductivity of 0.004W / mK, the total thickness of the lightweight structural material 100 will increase to 20 to 40mm, but in terms of thermal insulation, it will be possible to achieve thermal insulation performance that is 6 to 10 times better than that of general EPS (Expanded Polystyrene) thermal insulation materials. In addition, due to the nature of the composite material, the structural strength increases in proportion to the 2 to 3 power of the increase in thickness, so although the weight is light, superior structural performance can be achieved.

[0186] In addition, when the vacuum insulation material is contained in a non-foamed polymer, the vacuum insulation material can be more effectively protected from external impact, and the airtight structure of the non-foamed polymer completely blocks the gas inlet and outlet of the vacuum insulation material, thereby achieving the effect of almost semi-permanently extending the life of the vacuum insulation material.

[0187] When the core layer 140 is composed of only a non-foamed polymer, the advantage is that the manufacturing thickness of the lightweight structural material 100 can be optimized to a very thin thickness. When the non-foamed polymer and a high-performance thermal insulation material 141 such as a vacuum thermal insulation material are included, it has the advantages of being simpler in manufacturing the lightweight structural material 100 (because the non-foamed polymer stock solution can be applied to the surface of the high-performance thermal insulation material 141 and used like an adhesive) and can achieve excellent thermal insulation performance. Therefore, the advantages of each method can be considered, and when forming the core layer 140 of the lightweight structural material 100 according to the present invention, it is selected and applied whether to use the non-foamed polymer alone or in parallel with the high-performance thermal insulation material 141.

[0188] For reference, if the core layer 140 is composed only of the high-performance thermal insulation material 141, it is difficult to ensure sufficient structural performance due to the weak bonding strength with the upper plate 110 and the reinforcement plate 120. Only when the non-foamed polymer surrounding the high-performance thermal insulation material 141 is firmly fixed between the upper plate 110 and the reinforcement plate 120 through bonding, can the lightweight structural material 100 of the present invention obtain satisfactory structural performance.

[0189] Ⅴ. Application examples of lightweight structural materials

[0190] The lightweight structural material 100 according to the present invention can be used to form the ground, ceiling and wall structure of a ship structure or a building. Preferably, the lightweight structural material 100 according to the present invention can be used as a deck structure of a ship. In addition, the lightweight structural material 100 according to the present invention can be installed on the upper or lower part of the concrete slab that distinguishes the upper and lower floors in a building, and used as a floor or ceiling structure. Of course, it can also be applied to the wall structure of a building as needed. The following describes a specific application example of the lightweight structural material 100 according to the present invention and its effects.

[0191] (1) Ship structure

[0192] The lightweight structural material 100 according to the present invention can be applied to the floor structure of a ship deck or a ship accommodation area. In particular, the lightweight structural material 100 according to the present invention is expected to be very useful in the field of shipbuilding, especially in the manufacture of car decks (Car-Deck) of car carriers (PCC, Pure Car Carrier), and is also effective in forming the floor structure of a ship accommodation area.

[0193] When the lightweight structural material 100 according to the present invention is used as a ship structural material, the existing welding thermal deformation problem can be solved.

[0194] Traditionally, to form a ship deck, mainly used Figure 1In the case of a general steel plate structural material of the form shown in FIG, since the plate reinforcing material 20 is welded under the upper plate 10 that serves as a structural member, as described above, a serious thermal deformation problem is unavoidable. In addition, if only the structural performance usually used as a ship deck is considered, the upper plate 10 of the steel plate structural material can be formed to a thickness of about 6 mm, but considering the thermal deformation caused by the welding of the plate reinforcing material 20, it is also common to increase the thickness of the upper plate 10 to about 10 mm in the initial manufacturing. However, even if the thickness of the upper plate 10 is increased, the thermal deformation problem caused by the welding of the plate reinforcing material 20 still exists, and therefore, in most cases, a lot of time is invested in the repair work by hot working after welding the plate reinforcing material 20.

[0195] However, the lightweight structure 100 according to the present invention is a form in which the protrusion having the function of the plate reinforcement material is already included in the structure, and welding is not required for the attachment of the plate reinforcement material, thereby greatly reducing the amount of welding required for the entire project and the resulting thermal deformation. Therefore, the problem of thermal deformation caused by welding of steel plate structural materials still mainly used in the shipbuilding industry can be fundamentally solved.

[0196] In addition, when connecting adjacent lightweight structural materials 100, the present invention can also perform welding between finishing parts made of metal materials, or perform welding between lightweight structural materials 100 whose rigidity has been ensured through the core layer 140 formed internally, thereby greatly reducing the thermal deformation of the entire plate.

[0197] In addition, the lightweight structural material 100 according to the present invention, which is made of composite materials, is about 40% to 50% lighter than the existing steel plate, so it can achieve equivalent structural performance, which also greatly contributes to the lightweighting of ships.

[0198] (2) Building structure

[0199] The space between the upper plate 110 and the reinforcement plate 120 of the lightweight structural material 100 according to the present invention is mostly filled with non-foamed polymers, and therefore has a thermal conductivity of 0.2 to 0.4 W / mK, which is similar to that of high-density trees. This means that compared with general steel plate structural materials (k=83 W / mK) mainly used for ships, it has incomparably excellent thermal insulation performance, and compared with reinforced concrete (k=1.6 W / mK) used for construction, it also has better thermal insulation performance. In addition, due to the effect of the elastic non-foamed polymer, the lightweight structural material 100 according to the present invention also has excellent performance in vibration reduction / noise reduction, and can be used not only for ship structural materials, but also for land floor or wall structures, etc.

[0200] Representatively, the two ends of the lightweight structural material 100 according to the present invention along the length direction can be structurally connected to the wall to form the floor or ceiling structure of the building. The following introduces the embodiments of using the lightweight structural material 100 according to the present invention as the floor structure and ceiling structure of the building.

[0201] A. Floor structure of the building (double floor)

[0202] The lightweight structural material 100 according to the present invention can be used for the floor structure of a building, and in particular, can be made into a large-span structure, and is therefore very useful in forming a double-layer floor structure of a building.

[0203] Reference Fig.18 The two ends of the lightweight structural material 100 according to the present invention along the length direction can be fixed to the wall of the upper building. At this time, it can be placed on the upper side of the concrete slab constituting the upper floor with a small gap to realize a double floor structure.

[0204] Generally, multi-story buildings such as apartments, houses, office buildings, and mansions are separated from the upper and lower floors by concrete slabs, with the upper floor using concrete slabs as the floor and the lower floor using concrete slabs as the ceiling. In other words, a general multi-story building is a structure where the ceiling structure of the lower floor is formed by the floor structure of the upper floor, and since two floors share one concrete slab, it is fundamentally vulnerable to the transmission of noise through it.

[0205] As a way to solve the noise problem between floors, double-layer floor structure is the most widely used. As we all know, the traditional double-layer floor structure is a structure in which a lightweight floor is set on a concrete slab, that is, two floors are formed, and an air layer is set between them to isolate the sound transmission.

[0206] However, this conventional double-layer floor structure requires dozens to hundreds of brackets to be installed between the lightweight floor and the concrete slab for support because the lightweight floor is not as strong as the concrete floor. Therefore, the noise / vibration transmitted through the numerous brackets cannot be ignored. In addition, since multiple brackets need to be installed, there is also the problem of increased installation time and cost.

[0207] However, the lightweight structural material 100 according to the present invention can be made into a large-span structure, so as long as the two ends along the length direction are fixed to the building wall, sufficient structural performance can be ensured, so even without a separate lower supporting structure, a strong and perfect double-layer floor structure can be achieved.

[0208] That is, when the upper floor is formed by using the lightweight structural material 100 according to the present invention to realize a double-layer floor structure, there is no need to separately install a bracket supporting the lightweight structural material 100 on the concrete slab. Therefore, the upper floor and the concrete slab are completely separated in structure, and a double-layer floor structure that is very effective in reducing noise between floors can be realized.

[0209] Continue to refer to Fig.18 , more specifically illustrating the effect of applying the lightweight structural material 100 according to the present invention on reducing inter-floor noise.

[0210] Generally speaking, inter-floor noise can be divided into two types: first, the noise that is transmitted once through the floor structure by the weight or friction impact sound generated by the upper floor; and second, the noise that is transmitted twice from the upper floor through the wall. In the double-layer floor structure implemented using the lightweight structural material 100 according to the present invention, the impact sound generated on the side of the lightweight structural material 100 constituting the upper floor of the upper floor is converted into sound and transmitted to the concrete slab on the lower side. That is, since the impact sound is transmitted in the form of sound energy rather than by direct vibration, the total energy transmitted to the lower floor can be greatly reduced.

[0211] In addition, the vibration transmitted from the upper lightweight structural material 100 constituting the upper floor through the wall is not directly transmitted to the lower ceiling finishing material, but is first transmitted to the concrete slab, so the energy of vibration and sound applied to the lower ceiling finishing material can be greatly reduced.

[0212] Furthermore, the present invention proposes several buffer structures that can alleviate the impact when the lightweight structural material 100 is connected to the wall, thereby more effectively blocking the noise transmitted by the lightweight structural material 100 through the wall and minimizing the noise between floors.

[0213] The following reference Figures 19 to 22 , the applicable connection structure between the lightweight structural material 100 according to the present invention and the wall is reviewed.

[0214] First, refer to Fig.19 See the first wall connection structure. In the first wall connection structure, an anchor pad 211 is installed on the building wall, and a metal plate 212 for fastening the anchor pad 211 is fixed by welding at both ends along the length direction of the lightweight structural material 100. The anchor pad 211 and the metal plate 212 are fixedly connected to each other by bolt connection. At this time, a shock-absorbing and buffering material can be placed between the anchor pad 211 and the metal plate 212 to alleviate the impact transmitted from the lightweight structural material 100 to the wall.

[0215] Next, refer to Fig. 20See the second wall connection structure. In the second wall connection structure, the lower part of the anchor pad 221 installed on the building wall is set in the form of an L-shaped angle (or the L-shaped angle component is combined with the lower end of the anchor pad 221), and the lower end of the metal plate 222 is inserted into the space formed by the lower L-shaped angle of the anchor pad 221, which can prevent separation in the horizontal direction and be supported. The upper end of the metal plate 222 can be fixed to the anchor pad 221 or the wall by bolt connection.

[0216] In addition, a shock-absorbing buffer material or a spring may be additionally provided between the metal plate 222 and the anchor pad 221 to mitigate the impact transmitted from the lightweight structural material 100 to the wall.

[0217] The second wall connection structure is a method in which the bottom of the metal plate 222 is accommodated and supported in a form of being simply inserted into the space, without mechanical fastening by a separate component, and only the upper end is fastened by bolts. Since the metal plate 222 only needs to be placed on the anchor pad 221 including the L-shaped corner and the upper end is fixed to the wall, the on-site workability is very simple and a structurally strong connection can be achieved.

[0218] Next, refer to Fig.21 Check out the third wall connection structure. In the third wall connection structure, an anchor pad 231 installed on the building wall and a metal plate 232 welded and fixed to the end along the length direction of the lightweight structural material 100 are configured to be connected in a hinge manner so that the metal plate 232 can rotate around the hinge axis, and a spring 233 with elasticity is provided between the anchor pad 231 and the metal plate 232 to mitigate the impact transmitted from the lightweight structural material 100 to the wall.

[0219] In the third wall connection structure, a shock-absorbing and buffering material may be provided between the anchor pad 231 and the metal plate 232 to replace the spring 233 , or the shock-absorbing and buffering material may be placed together with the spring 233 .

[0220] If the second wall connection structure shown in 20 is a structure that does not constrain the lower end of the metal plate 222 and allows slight movement within a predetermined range, then Fig.21 The third wall connection structure shown can be understood as a structure that constrains the lower end of the metal plate 232, but enables the entire plate to flexibly cope with vibrations through a hinge connection.

[0221] at last, Fig. 22 The fourth wall connection structure shown is a method of connecting the lightweight structural material 200 to the building wall through a vibration reduction device 241, rather than a direct connection. Here, the vibration reduction device 241 can be a hydraulic device or a spring device that can absorb vibrations in the up and down directions.

[0222] When the fourth wall connection structure is applied, the vibration caused by the impact generated by the lightweight structural material 100 is not transmitted to the wall. In addition, since the vibration transmitted from the lightweight structural material 100 to the concrete slab can be absorbed by the vibration reduction device 241, the impact transmitted in the up and down directions can also be effectively alleviated.

[0223] In addition, although not shown in the drawings, in addition to the above-mentioned first to fourth wall connection structures, additional damping effects may be achieved by placing various buffer materials in the space between the lightweight structural material 100 and the concrete slab to further reduce inter-floor noise.

[0224] B. Ceiling structure of the building

[0225] Although not shown separately, the lightweight structural material 100 according to the present invention may also be installed below a concrete slab and used as a ceiling structure of a lower level.

[0226] In this case, since the lower-layer ceiling finishing material can be directly attached to the lower side of the lightweight structural material 100, separate bracket works and carpentry works for attaching the ceiling finishing material are not required, which has the effect of simplifying the ceiling works.

[0227] In addition, since various pipes and equipment (eg, ceiling-type air conditioners) that need to be constructed on the ceiling can be easily attached to the lightweight structural material 100 according to the present invention, a modular process can also be applied through pre-outfitting.

[0228] C. Used as overlapping structures

[0229] like Fig.23 As shown, the lightweight structural material 100 according to the present invention can also be stacked up and down for use.

[0230] As such, if the lightweight structural material 100 is stacked in two, various devices can be pre-constructed in the space facing the upper / lower lightweight structural material 100, thereby having the advantage of easily adding a variety of additional functions.

[0231] For example, refer to Fig.24 By installing the heat insulating material I and the cooling / heating pipe P in the space between the light structural materials 100 stacked up and down, the function of heating the bed can be easily added. Here, the heat insulating material I can be placed only on the lower side of the cooling / heating pipe P, so that the cold or warm heat generated by the hot fluid flowing through the cooling / heating pipe P can be transferred upward, and space can be left in the surrounding area of ​​the cooling / heating pipe P.

[0232] Usually, the ondol ventilation project requires laying insulation materials on the concrete slab, installing hot water pipes on top, and then finishing mortar construction on top. Here, in order to achieve uniform flatness during mortar construction, mortar containing a large amount of water is required, so its curing time is long, which brings a lot of inconvenience to the work.

[0233] However, when the present invention is applied, since the lightweight structural material 100 disposed on the upper portion performs a structural function, no separate mortar construction is required, and thus the construction of the ondol structure and / or the floor cooling / heating structure can be performed very conveniently and simply.

[0234] In addition, based on this, refer to Fig.25 It is also possible to achieve fireproof performance of the floor by adding a fireproof material R between the lightweight structural material 100 and the insulation material I disposed at the bottom without the need for a separate fireproof coating.

[0235] According to domestic and international floor fire protection standards, whether the temperature of the non-heated surface of the structural material rises is important, but it is also important to consider the fire stability of the structure. More specifically, a weight with a load of more than a certain load (for example, 3kN / m 2 ) state, the lower part of the structural material is exposed to a heat source, and the deflection of the structural material is confirmed after a certain period of time (for example, 2 hours) to evaluate the structural stability.

[0236] Conventional building structural materials are usually made of metal, which loses its structural performance when heated above a certain temperature during fire resistance testing. Therefore, in order to meet fire protection standards, subsequent work is being implemented to cover the lower part of the metal with fireproof materials.

[0237] However, if Fig.25 As shown, when the fire-resistant material R is placed inside the overlapping structure according to the overlapping placement of the lightweight structural material 100, even if the lightweight structural material 100 arranged at the bottom loses its structural performance due to exposure to the heat source caused by the fire, the upper lightweight structural material 100 protected by the fire-resistant material R can maintain its structural performance. Therefore, even if no additional fire-resistant coating work is performed as conventionally, structural stability can be maintained in the event of a fire, and it has the advantage of easily meeting the above-mentioned fire protection standards.

[0238] When the lightweight structural materials 100 according to the present invention are placed in an overlapping manner, when it is necessary to give additional functions to the space therebetween, or when it is necessary to include a double-layer floor structure in the structure itself to double the noise reduction effect between floors, the lightweight structural materials 100 facing each other can be placed with a predetermined gap. In addition, since each lightweight structural material 100 constituting the overlapping structure will be fixed separately in the structure, the lightweight structural materials 100 placed in an upper and lower position do not necessarily need to be directly connected in the structure.

[0239] When the lightweight structural material 100 according to the present invention is placed in a doubly overlapping manner and used as the floor structure of a building, since the impact sound which is the direct cause of the inter-floor noise will be generated by the lightweight structural material 100 placed on the upper side, the upper lightweight structural material 100 can adopt the aforementioned first to fourth wall connection structures to connect it to the building wall for buffering, and the lightweight structural material 100 placed on the lower side can be connected to the wall by simple mechanical fastening such as bolt connection.

[0240] When the lightweight structural material 100 according to the present invention is used as a building structural material, the following effects can be expected.

[0241] Firstly, it is possible to achieve an ultra-light, large-span dry structure with significantly superior structural performance, which can greatly increase the overall efficiency of the construction project after use.

[0242] In construction projects, reinforced concrete floor construction is the most tedious and time-consuming basic framework project of the entire project. In particular, since this project is manufactured using a wet process that is greatly affected by the environment and has harsh on-site conditions, it is also considered the most important project in terms of project management and performance. Recently, there have been cases where wet concrete slab construction was forced forward in order to shorten the construction period, resulting in a major accident.

[0243] Although the weight of the lightweight structural material 100 proposed by the present invention is only about 30% to 40% of that of general concrete, it can realize a long-span structure that is much longer than the existing reinforced concrete floor structure, and most importantly, it can adopt a dry process, so it is almost unaffected by the environment, and has the advantage of greatly reducing cumbersome and harsh on-site engineering. In addition, unlike the wet process, the structural performance is immediately reflected after installation, so the entire construction period can be significantly shortened.

[0244] In addition, by using the lightweight structural material 100 according to the present invention, a strong double-layer floor structure without a support can be realized, and thus, the inter-floor noise problem that has become a social hot spot can be greatly reduced.

[0245] In addition, when the lightweight structural material 100 according to the present invention is used as the floor structure of a building, the heating and ventilation engineering can be simplified. As mentioned above, the lightweight structural material 100 according to the present invention has significantly excellent structural performance, so there is no need to perform heating and ventilation construction (heating construction) on the lightweight floor like the existing double-layer floor structure to increase the structural strength. Therefore, when the lightweight structural material 100 according to the present invention is installed on an existing concrete slab, it has the following advantages: the hot water pipe or cooling / heating pipe engineering required for the heating and ventilation construction can be conveniently carried out on the existing concrete without the need for a separate ventilation mortar engineering.

[0246] The traditional construction of heated ondol ventilation is to install hot water pipes after the construction of heat insulation materials on the concrete slab. Therefore, in order to form a flat floor on which one can walk, floor mortar work or additional installation of a separate dry ondol slab is required before finishing the floor material construction. However, since the lightweight structural material 100 according to the present invention itself fully functions as a structural material, there is no need for the separate floor mortar work or dry ondol slab installation work that was previously performed, and since the finishing floor material construction can be performed directly on the lightweight structural material 100, the heated ondol ventilation project can be made simpler.

[0247] The step construction can also be simplified. Usually, the floor of a bathroom or entrance hall is designed to have a step that is several tens of millimeters (mm) lower than other floor slabs, and using traditional processes, a separate formwork operation or ventilation operation is required to form such a step. However, according to the present invention, all floor slabs on the same layer are made flat, and only the step construction needs to be performed on the lightweight structural material 100, which can simplify the step construction and also has the advantage of being very convenient to manufacture the floor step structure of the bathroom or entrance hall.

[0248] In addition, when the lightweight structural material 100 according to the present invention is used as the ceiling structure of a building, the ceiling project can be simplified because the lower-layer ceiling finishing material can be directly attached to the bottom of the lightweight structural material 100. A modular process can also be applied by attaching various pipes and equipment that need to be constructed on the ceiling to the pre-outfitting on the lightweight structural material 100.

[0249] In addition, when the lightweight structural material 100 according to the present invention is stacked up and down and used as an overlapping structure, it has the advantage that various pipes or ceiling attachments can be pre-constructed inside or below the structure.

[0250] For example, the insulation material I and cooling / heating pipes P required for floor heating can be easily installed into the structure through pre-outfitting (refer to Fig.24 ), a separate ondol ventilation project can be omitted, which can greatly simplify the entire construction project. In addition, the floor temperature will respond faster to temperature regulation, and the structure that needs to be preheated will become lighter and simpler, which is also very beneficial in terms of thermal efficiency. In addition, if additional fireproof material R is arranged in the structure through pre-outfitting (refer to Fig.25 ), the advantage is that the self-fire protection performance can be fully realized without the need for separate post-fire protection treatment.

[0251] The present invention is not limited to the described embodiments, and it is obvious to those skilled in the art that various modifications and changes can be made without departing from the spirit and scope of the present invention. Therefore, such modifications or changes should be considered to fall within the scope of the patent claims of the present invention.

Claims

1. A composite material-based plate reinforcement material integrated lightweight structural material, characterized in that: include: Flat metal upper plate, a plurality of reinforcing plates made of metal material, including a horizontal plate formed in a horizontal direction and a vertical plate bent downward from the horizontal plate, and arranged to be spaced apart at predetermined intervals toward the lower side of the upper plate, and A core layer of non-metallic material is formed in the space between the upper plate and the reinforcing plate and in the space between adjacent reinforcing plates; The vertical plates formed in plurality form a pair in a manner close to and facing each other, and the pair of vertical plates and the core layer formed therebetween constitute a protrusion that acts as a plate reinforcing material, and the protrusion is formed at a certain interval in the horizontal direction and extends while maintaining a certain cross-sectional shape in the length direction.

2. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: The core layer is formed from a non-foamed polymer.

3. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: The horizontal plate and the vertical plate constituting the reinforcing plate are formed by bending a single plate.

4. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: The lower end of the protrusion is bent again or a separate metal finishing component is combined at the lower end of the protrusion, so that the lower end of the protrusion has an "L"-shaped cross section or a "⊥"-shaped cross section. The vertical reinforcement portions formed in the vertical direction from the protruding portions perform the function of a web of the plate reinforcing material, and the vertical reinforcement portions formed in the horizontal direction from the protruding portions perform the function of a flange of the plate reinforcing material.

5. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: Among the plurality of reinforcing plates, except for the reinforcing plates arranged at least at two ends along the width direction, the remaining reinforcing plates have Shaped cross section, It also includes a lower plate, which is arranged to be spaced apart at a predetermined interval toward the lower side of the reinforcing plate, The core layer is additionally formed between the reinforcing plate and the lower plate. The overall structure is made to include a ladder shape.

6. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 2, characterized in that: A high-performance thermal insulation material with a thermal conductivity of less than 0.02 W / mK is additionally arranged in the core layer.

7. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 3, characterized in that: The high-performance thermal insulation material is a vacuum thermal insulation material.

8. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: Also includes: Side end finishing parts are used to finish the ends of both sides of the upper plate and the reinforcement plate; The side end finishing member is inserted between the upper plate and the reinforcing plate, and is pushed in a predetermined distance from the ends of the upper plate and the reinforcing plate.

9. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 8, characterized in that: When connecting the adjacent lightweight structural materials, the upper plates facing each other and the lower plates facing each other are joined by welding. A non-foaming polymer stock solution is injected into the space formed between the upper plate, the lower plate and the side end finishing component and solidified to airtightly finish the connection portion.

10. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 1, characterized in that: Also includes: The side end finishing parts are used to finish the ends of both sides of the upper plate and the reinforcing plate, wherein: The side end finishing part is set to a straight line shape or has a " "-shaped cross-section, with one end inserted between the upper plate and the reinforcing plate, and the other end protruding to the outside of the upper plate and the reinforcing plate.

11. The integrated lightweight structural material of the plate reinforcement material based on composite materials according to claim 10, characterized in that: When connecting the adjacent lightweight structural materials, the side end finishing parts facing each other are connected by welding or bolts.

12. A ship deck structure, characterized in that: The method is manufactured using the lightweight structural material according to any one of claims 1 to 11.

13. The ship deck structure according to claim 12, characterized in that: The vessel described is a special vessel for transporting automobiles.

14. A method for manufacturing a composite material-based plate reinforcement material integrated lightweight structural material, characterized in that: The lightweight structural material comprises: Flat metal upper plate, a plurality of reinforcing plates made of metal material, arranged to be spaced apart at predetermined intervals toward the lower side of the upper plate, and including a horizontal plate formed in a horizontal direction and a vertical plate bent downward from the horizontal plate, and a core layer forming a space between the upper plate and the reinforcing plate and a space between adjacent reinforcing plates; The method comprises the following steps: The space between the upper plate and the reinforcing plate and the space between adjacent reinforcing plates are filled with a non-foamed polymer stock solution. curing the non-foamed polymer stock solution, and The non-foamed polymer stock solution is solidified to complete the formation of the core layer.

15. The method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material according to claim 14, characterized in that: In the above-mentioned step of filling with non-foaming polymer stock solution, a space is formed on the upper plate and the non-foaming polymer stock solution is poured into it. Then, the reinforcement plate is inserted from above in an inverted state and pressurized to a position at a predetermined distance from the upper plate, so that the non-foaming polymer stock solution overcomes the friction resistance caused by viscosity under the pressure of the reinforcement plate, dissolves into the space between the reinforcement plates, and fills the space evenly.

16. The method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material according to claim 15, characterized in that: The amount of the non-foamed polymer solution initially poured into the space on the upper plate is at least 2% more than the actual volume occupied by the core layer, and the excess amount is pushed outward and discharged by the pressure of the reinforcing plate.

17. The method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material according to claim 14, characterized in that: In the step of filling the non-foaming polymer solution, the space where the core layer is to be formed is sealed, the non-foaming polymer solution is injected into the sealed space using an injection tube, and the injection tube is divided into multiple small tubes and arranged in the sealed space.

18. The method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material according to claim 14, characterized in that: In the above-mentioned step of filling the non-foaming polymer stock solution, the space to be formed into the core layer is sealed, an injection tube is inserted into one side of the sealed space and the non-foaming polymer stock solution is injected, and the air in the sealed space is sucked in by a vacuum pump on the other side.

19. The method for manufacturing the composite material-based plate reinforcement material integrated lightweight structural material according to claim 14, characterized in that: In at least one of the above-mentioned steps of filling the non-foaming polymer stock solution and the above-mentioned step of curing the non-foaming polymer stock solution, a magnet is set on the surface of at least one of the upper plate and the reinforcing plate or a vacuum adsorption device is used to apply tension to maintain flatness and maintain an accurate angle.

Images