Lightweight structure made of composite material

Abstract

Disclosed is a lightweight structure made of a composite material, characterized by comprising: an upper plate made of a metal; a lower plate provided to be spaced apart from the upper plate at a predetermined interval and made of metal; the invention relates to a composite board, which comprises an upper board, a lower board and a core layer, the core layer is formed between the upper board and the lower board and is made of non-foaming polymer, the composite board further comprises a multi-element structure material, the multi-element structure material is composed of a plurality of unit structure materials which are continuously arranged in the width direction, and each unit structure material comprises a U-shaped section structure. The two ends of the bending structure are bent downwards in the width direction of the whole structure.

Description

Technical Field

[0001] The present invention relates to a lightweight structure made of composite materials, and more particularly to a lightweight structure of floors, ceilings and walls based on composite materials which is ultra-light but has high structural performance and can be used in various ways in the fields of ships and buildings. Background Art

[0002] Floor engineering, which is the most basic engineering for structures such as buildings and ships, is one of the most important engineering. To construct the floor of a structure, buildings mainly use reinforced concrete, and ships generally use structural materials composed of steel plates and plate reinforcement materials.

[0003] The floors of structures have various problems in terms of construction methods and performance, the most important of which is the problem of inter-floor noise. Since ship floor materials are composed only of steel, they are the most vulnerable to inter-floor noise, while steel concrete, which is a floor material for buildings, has excellent performance in terms of inter-floor noise, but it is still difficult to completely block inter-floor noise, causing serious social problems. In particular, structure-borne noise caused by the impact of heavy objects, that is, weight impact sound, is considered to be the biggest problem.

[0004] Meanwhile, the biggest cause of inter-floor noise in multi-story buildings is that the floor structure of the upper floor forms the ceiling structure of the lower floor. That is, since both floors share a common concrete slab, it is fundamentally susceptible to noise transfer. Of course, there is also structure-borne noise that is transmitted through walls instead of floors and noise that is transmitted through gaps in the building, but it is well known that structure-borne noise transmission due to shared floor structures is the biggest cause of inter-floor noise.

[0005] As is well known, wet floating floor structures (laminated floor structures) and double floor structures are ways to solve the problem of noise between floors.

[0006] The wet floating floor structure is a method of mixing and layering a variety of different materials inside and outside the existing concrete slab to absorb or isolate sound transmission. However, the fundamental problem of the wet floating floor structure is that it cannot completely isolate noise between floors, because noise and vibration will inevitably be transmitted along the floor component layers connected in a layered manner.

[0007] The double floor structure is a structure in which an additional light floor is installed on a concrete slab that supports the structural strength of the building, that is, two floors are formed with an air layer between them to isolate sound transmission. However, since the structural strength of the light floor is not as strong as that of the concrete floor, the conventional double floor structure requires dozens to hundreds of brackets to be installed between the light floor and the concrete slab for support, and therefore, the noise / vibration transmitted through the numerous brackets cannot be ignored.

[0008] In addition, the traditional double-layer floor structure greatly increases the installation time and cost. In addition, when performing heating projects on the upper part of the lightweight floor for structural reinforcement, there are many problems such as leveling problems, construction problems, and finishing work problems. Summary of the invention

[0009] Technical problems to be solved

[0010] Nevertheless, in order to significantly reduce inter-floor noise, a double-layer floor structure that is completely separated in structure and has sufficiently strong structural properties is most effective.

[0011] However, the problem is that it is actually difficult to double-install a solid floor structure using existing materials and construction methods. Because in general multi-story buildings, the span or wall gap between rooms is usually about 3 to 8 meters, if a solid double-layer floor structure is installed in these spaces, a structural reinforcement project almost equivalent to the existing floor project is required. In addition, it is unrealistic to use reinforced concrete to make a double-layer floor structure from the beginning when constructing a building, both in terms of economy and technology.

[0012] For ships, if the secondary floor (upper floor) is made of existing steel plate structural materials, at least 100mm or more plate reinforcement materials must be closely welded at intervals of 600 to 800mm on an iron plate of at least 6mm to obtain satisfactory structural strength. At this time, a large amount of welding deformation will occur, so in order to eliminate thermal deformation, a large amount of post-bending work is required. In addition, since the secondary floor made of iron itself is quite heavy, the economic efficiency is very poor in terms of structural design.

[0013] Therefore, the present invention aims to provide a high-performance lightweight structure based on composite materials, which can overcome the above-mentioned technical limitations and can be innovatively applied to future ship and construction fields.

[0014] In particular, the present invention aims to provide a lightweight structure based on composite materials that is easy to manufacture, has excellent structural properties, and allows the manufacture of large span structures, making it easy to achieve a strong double-layer floor structure, which is traditionally technically difficult to achieve without brackets.

[0015] In addition, the present invention aims to provide a lightweight structure that can be used not only as a floor structural material but also as a ceiling or wall structural material, and can also solve various problems such as improvements in floor engineering, heated ondol ventilation engineering, and improvements in the installability of ceiling materials by utilizing the particularity of the structure.

[0016] The technical problems to be solved by the present invention are not limited to the above-mentioned technical problems, and those skilled in the art will clearly understand other technical problems not mentioned from the following description.

[0017] Technical solution for solving the problem

[0018] To achieve the above object, according to one aspect of the present invention, a lightweight structure made of a composite material can be provided, which is characterized in that it includes: an upper plate made of metal; a lower plate arranged at a predetermined interval from the upper plate and made of metal; and a core layer formed between the upper plate and the lower plate and made of a non-foamed polymer. It further includes: a multi-structural material composed of a plurality of unit structural materials arranged continuously in the width direction, wherein the unit structural material includes a "C"-shaped cross-sectional structure, which includes a bending structure that bends downward at both ends along the entire width direction of the structure.

[0019] The unit structural material may include: a flat plate portion formed in the horizontal direction; and a bending portion that bends downward from both ends of the flat plate portion.

[0020] At this time, the bending portions of the adjacent unit structural materials can be structurally combined by bolts or welding.

[0021] Alternatively, the adjacent unit structural materials can be arranged at a predetermined interval, and the space between the adjacent unit structural materials can be finished to form a floor, ceiling or wall.

[0022] Both ends of the multi-structural material in the length direction can be fixed to the wall of the building to form the floor structure or ceiling structure of the building.

[0023] When forming the floor structure of the building, the multi-structural material can be arranged with a gap on the upper side of the concrete slab constituting the basic frame of the building to form a double-bottom floor structure.

[0024] The connection part between the multi-structural material and the wall can adopt a vibration-absorbing buffer structure, including a shock-absorbing buffer material, a spring or a hydraulic device.

[0025] Meanwhile, the lightweight structure made of the composite material according to one aspect of the present invention can include: an overlapping structural material formed by stacking the multi-structural materials up and down.

[0026] A pair of the multi-structural materials can be arranged in a direction where the bending portions face each other.

[0027] The space between a pair of the multi-structural materials can be pre-fitted with heat-insulating materials and heating / cooling pipes to be modularized.

[0028] Additional construction of fireproof materials can be carried out between the heat-insulating material and the multi-structural material.

[0029] Both ends of the overlapping structural material in the length direction may be fixed to the wall of a building to form a floor structure or a ceiling structure of the building.

[0030] Both ends in the length direction of each of the upper multi-structure material and the lower multi-structure material constituting the overlapping structural material may be fixed to the wall.

[0031] When forming the floor structure of the building, a buffer structure capable of absorbing vibrations may be used at the connection portion between the upper multi-structure material and the wall, including a shock-absorbing buffer material, a spring or a hydraulic device.

[0032] Technical Effects

[0033] According to the present invention as described above, a strong double floor structure can be easily realized without requiring a separate plate reinforcing material or a supporting lower structure (beam), thereby having the effect of effectively reducing noise between floors.

[0034] In addition, when the lightweight structure according to the present invention is used in the construction field, an ultra-light and high-structural-performance floor structure can be realized, the structural connections between floor structures can be minimized, the ondol ventilation project can be simplified, and various ancillary effects can be achieved, such as realizing the ultimate dry construction method and modular construction method that are not affected by weather.

[0035] In addition, since the lightweight structure according to the present invention is ultra-light, when used as a structural material for buildings and ships, the overall weight of the structure can be reduced, and compared with the steel plate structural materials used in existing ships, the price is very low, which also has an advantage in cost.

[0036] 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

[0037] Figure 1 is a perspective view of a unit structural material according to the present invention.

[0038] Figure 2 These are front views of various modified examples of the unit structural material according to the present invention.

[0039] Figures 3 to 6 These are diagrams for explaining the first to fourth methods for producing the unit structural material of the present invention, respectively.

[0040] Figure 7 and Figure 8 2 are diagrams respectively showing first and second bonding structures of a multi-structure material according to the present invention.

[0041] Fig. 91 is a diagram showing an example in which the multi-element structural material according to the present invention is applied to a floor structure of a building.

[0042] Figures 10 to 13 1 and 2 are diagrams respectively showing first to fourth wall connection structures of the multi-structure material according to the present invention.

[0043] Fig.14 1 is a diagram showing an embodiment in which the multi-element structural material according to the present invention is applied to a ceiling structure of a building.

[0044] Fig.15 is a diagram showing an arrangement structure of overlapping structural materials according to the present invention.

[0045] Fig.16 and Fig.17 1 and 2 are diagrams respectively showing first and second use examples of the stacked structural material according to the present invention.

[0046] Fig.18 is a diagram showing a wall connection structure of overlapping structural materials according to the present invention.

[0047] Fig.19 is a cross-sectional view showing a steel plate structural material applied to a conventional ship. DETAILED DESCRIPTION

[0048] 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.

[0049] 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.

[0050] 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.

[0051] The lightweight structure made of the composite material according to the present invention may include a unit structure material as a unit body, a multi-structure material composed of a combination of a plurality of unit structure materials, and an overlapping structure material composed of a double overlapping arrangement of multi-structure materials.

[0052] Figures 1 to 6 This is a diagram related to the description of the "unit structural material" according to the first embodiment of the lightweight structure of the present invention. Figures 7 to 14 This is a diagram related to the description of the "multi - structure material" according to the second embodiment of the lightweight structure of the present invention. Figures 15 to 18 This is a diagram related to the description of the "overlapping structure material" according to the third embodiment of the lightweight structure of the present invention.

[0053] 1. First Embodiment - Unit Structural Material

[0054] A. Structure of the Unit Structural Material

[0055] Referring to Figure 1 to Figure 2 , the unit structural material 100 according to the present invention can be made of a composite material, including an upper plate 110 and a lower plate 120 made of metal, and a core layer 130 formed between the upper plate 110 and the lower plate 120. Here, the core layer 130 can be a layer formed of a non - foamed polymer, more preferably a non - foamed polyurethane.

[0056] The unit structural material 100 according to the present invention can integrally include a "C" - shaped cross - section structure, which includes a bending structure with both ends along the width direction bent downward, and the bent portions at both ends can act as plate reinforcement materials.

[0057] Here, the expression "may include" a "┐" - shaped cross - section structure means that the cross - section structure of the unit structural material 100 is not necessarily limited to the "C" shape, and any cross - section structure can be adopted as long as it includes the "C" shape.

[0058] The unit structural material 100 according to the present invention can include a flat plate portion 100F formed in the horizontal direction and bending portions 100B bent downward from both ends of the flat plate portion 100F. The flat plate portion 100F is the structural component that mainly contacts the design load when using the unit structural material 100 according to the present invention to form a floor or ceiling structural material. The bending portions 100B act as plate reinforcement materials that improve the structural performance and prevent buckling by increasing the strength and stiffness of the flat plate portion 100F formed in the horizontal direction.

[0059] As described above, the unit structural material 100 according to the present invention can have various forms as long as it includes a structure with both ends along the overall width direction bent downward, including Figure 2 the deformation examples shown. Hereinafter, referring to Figure 2 , the representative forms that the unit structural material 100 according to the present invention can take will be described.

[0060] Figure 2 (a) shows Figure 1The most basic form of the unit structural material 100 shown, in which both the upper plate 110 and the lower plate 120 are arranged in a "C" shape, and the core layer 130 formed between the upper plate 110 and the lower plate 120 can also be configured to have a "C" - shaped cross - section.

[0061] In addition, as Figure 2 (b) shows, the unit structural material 100 according to the present invention can be configured in a form in which the outer side surface of the core layer 130 having a "C" - shaped cross - section is exposed, where the upper plate 110 is not bent and is formed only in the horizontal direction, or, as Figure 2 (c) shows, it can be configured in a form in which the inner side surface of the core layer 130 having a "C" - shaped cross - section is exposed, where the lower plate 120 is not bent and is formed only in the horizontal direction.

[0062] As Figure 2 (b) or (c) shows, even if one side surface of the core layer 130 is exposed, since both ends of one of the upper plate 110 and the lower plate 120 are bent and protrude downward, the bending part 100B including it can exhibit sufficient structural performance as a plate reinforcement material.

[0063] When one or more of the upper plate 110 and the lower plate 120 are formed in a "C" - shaped bending form, preferably, the metal plates constituting the upper plate 110 and the lower plate 120 are bent by bending processing. This is because it makes the bending part 100B of the unit structural material 100 according to the present invention present a continuous shape with the flat plate part 100F, strengthens its structure, and eliminates the risk of thermal deformation or cracks caused by welding.

[0064] As Figure 2 (d) shows, the unit structural material 100 according to the present invention can also have a triangular protrusion shape, where the inner side surfaces of the bending parts 100B formed at both ends are inclined. Of course, in this case, as in the embodiments shown in Figure 2 (b) or (c), one of the upper plate 110 and the lower plate 120 can be formed only in the horizontal direction so that one side surface of the core layer 130 is exposed.

[0065] In addition, as Figure 2 (e) shows, the unit structural material 100 according to the present invention can be configured in a form in which the lower end of the bending part 100B is horizontally bent again toward the center of the width direction of the unit structural material 100, or, as Figure 2 (f) shows, the parts bent again from the lower ends of the bending parts 100B on both sides can meet and be connected to each other so that it is configured in a form in which the upper plate 110 having a "square" - shaped cross - section surrounds the lower plate 120 having a "square" - shaped cross - section.

[0066] In Figure 2In the embodiments shown in (e) and (f), the unit structural material 100 has a more extended form rather than just an "L" shape, but there is no change in including the "L" - shaped cross - section structure. In this structure, the portions formed at both ends in the vertical direction act as plate reinforcement materials, thereby achieving structural performance.

[0067] Referring to Figure 2 (g), the unit structural material 100 according to the present invention can also achieve an "L" - shaped cross - section structure, including a separate metal angle member 140. In this case, both the upper plate 110 and the lower plate 120 are formed only in the horizontal direction without bending, and the metal angle member 140 bent in an "┐" shape is inserted and joined between the upper plate 110 and the lower plate 120 at both ends, and the core layer 130 can be filled in the space formed between the upper plate 110, the lower plate 120 and the metal angle member 140.

[0068] That is, the upper plate 110, the lower plate 120 and the core layer 130 constituting the unit structural material 100 according to the present invention do not necessarily have to be formed in an "L" form, and a structure in which both ends are bent downward can also be achieved by combining separate components such as the metal angle member 140.

[0069] Finally, referring to Figure 2 (h), the unit structural material 100 according to the present invention can also adopt the following form: the ends between the upper plate 110 and the lower plate 120 are finished with a finishing member 150 made of metal or non - metal. The finishing member 150 finishes the end portion of the bent portion 100B formed by the bent portions of the upper plate 110 and the lower plate 120. During the process of manufacturing the unit structural material 100 according to the present invention, functions such as sealing the space between the upper plate 110 and the lower plate 120 or assisting the bonding between unit structural materials 100 can be performed.

[0070] In the unit structural material 100 according to the present invention, the bent portions 100B that are bent from both ends in the width direction and protrude downward play a role in increasing the section modulus of the entire structure, and the section modulus depends on the height or shape of the bent portion 100B as a reinforcement structure.

[0071] In order to effectively achieve the structural performance of the bent portion 100B as a plate reinforcement material, it preferably includes a metal material having a high yield stress. Therefore, in the present invention, at least one of the upper plate 110 and the lower plate 120 is included in the bent portion 100B, or a separate metal angle member 140 is used to construct the lower bent portion 100B.

[0072] Fig.19 A steel plate structural material 10 composed only of metal is shown, which is widely used as a structural material for general ships. Fig.19The conventional steel plate structural material 10 shown has a plate reinforcing material 20 bonded to the lower side by welding for structural reinforcement, but this conventional method has a problem in that welding deformation occurs when the plate reinforcing material 20 is connected to the lower side of the steel plate structural material 10 .

[0073] However, unlike the conventional steel plate structural material 10, which is formed by separately manufacturing the plates and reinforcement materials used as structural members and then combining them by welding or bolts, the unit structural material 100 according to the present invention integrates the flat plate portion 100F and the curved portion 100B, and already includes a plate reinforcement structure. Therefore, there is no risk of welding deformation problems as in the conventional method, and no additional hole construction or local structural reinforcement work is required for bolting the plates and reinforcement materials, and the unit structural material 100 can have structurally stable performance.

[0074] Another problem with the prior art is that when the composite structure of the upper plate and the lower plate is constructed with thin metal plates, it may not be possible to post-weld the plate reinforcement material to the thin metal plates. In order for the plate reinforcement material to function properly in the structure, a certain level of weld bond strength is required, and the weld leg length is generally required to be at least 70% of the thickness of the web structure of the plate reinforcement material. In order to post-weld a metal plate reinforcement material with a web thickness of 6 mm, a weld leg length of at least 4 mm is required.

[0075] In addition, if the thickness of the steel plate as the parent material is too thinner than the weld leg length, in addition to welding deformation, there is also the problem of destroying the stability of the overall structure. When general welding equipment such as CO2 welding is used to achieve a weld leg length above a certain thickness, the welding heat can easily lead to carbonization of the inner core. In this case, loss of bonding strength will occur, greatly reducing the stability of the structure.

[0076] However, since the unit structural material 100 according to the present invention itself already includes the bent portion 100B, an optimized composite structure can be manufactured in which the thickness of the upper plate 110 and the lower plate 120 is much thinner than the thickness required for welding.

[0077] In addition, the unit structure material 100 according to the present invention is characterized in that not only the flat plate portion 100F but also the bent portion 100B serving as a plate reinforcement material are composed of a composite material rather than a single metal material. Compared with using a plate reinforcement material composed only of metal, the advantage of this structure is that the structure can be lightweighted by about 40% to 50%.

[0078] The thicknesses of the upper plate 110 and the lower plate 120 of the unit structural material 100 according to the present invention can be respectively formed to be 0.4 to 20 mm. At this time, as described below, when the unit structural material 100 according to the present invention is combined into a multi-structural material 200 as a separate module or when the unit structural material 100 is connected to other structures, welding work may be required. Therefore, the thicknesses of the upper plate 110 and the lower plate 120 constituting the outer plates of the unit structural material 100 are preferably 0.4 mm or more to facilitate laser welding. In addition, in order to achieve the light weight of the structural material, which is one of the technical problems of the present invention, the thicknesses of the upper plate 110 and the lower plate 120 are preferably formed to be 10 mm or less. Therefore, the present invention proposes 0.4 to 10 mm as the most preferred thickness of the metal plates constituting the upper plate 110 and the lower plate 120.

[0079] The thickness of the core layer 130 of the unit structural material 100 according to the present invention can vary between 3 and 40 mm. At this time, when the core layer 130 is configured to have a "C" - shaped cross - sectional shape and includes both a horizontally formed portion and a vertically formed portion, the thicknesses of the core layer 130 formed in the two directions can be different. That is, the thickness of the core layer 130 of the flat part 100F and the thickness of the core layer 130 of the bent part 100B can be formed to be the same, but can also be adjusted differently. When different thicknesses need to be formed, preferably, the thickness of the core layer 130 of the bent part 100B, which acts as a plate reinforcement material, is thinner than the thickness of the core layer 130 of the flat part 100B.

[0080] The total width of the unit structural material 100 according to the present invention can be formed to be 300 to 1500 mm, and the height of the bent part 100B protruding downward can be formed to be 40 to 500 mm. This height is at a level where structural performance can be achieved to compensate for the overall deflection of the structural material. Here, the height of the bent part 100B can refer to the height from the bottommost part of the unit structural material 100 to the lower surface of the upper plate 110.

[0081] When the thicknesses, widths, heights, etc. of each component are designed within the above ranges, the maximum span (length) of the unit structural material 100 according to the present invention can reach 6 to 10 m. That is, the unit structural material 100 according to the present invention can be manufactured into a large - span structure of about 6 - 10 m. This is because the core layer 130 composed of a non - foamed polymer is firmly joined between the upper plate 110 and the lower plate 110, providing basic structural performance. 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 bent parts 100B protruding downward from both ends of the unit structural material 100 act as plate reinforcement materials.

[0082] The unit structural material 100 according to the present invention can be manufactured with a large span of 6 to 10 meters. Within this length range, even if no separate reinforcing material is added in the direction across the width of the structural material, it can exert structural performance equivalent to that of reinforced concrete. Therefore, as described below, if a multi-structured material 200 or an overlapping structural material 300 composed of a plurality of unit structural materials 100 is used as a floor structural material, a perfect double-layer floor structure can be achieved without a separate lower support.

[0083] As a preferred embodiment, when the thickness of the upper plate 110 and the lower plate 120 of the unit structure material 100 according to the present invention is formed to be 1 mm each, and the core layer 130 is formed as a thin core with a thickness of 5 mm, the total thickness of the unit structure material 100 is only 7 mm. However, in this structure, the width of the unit structure material 100 is 700 mm, the height of the curved portion 100B is 100 mm, and both ends are fixedly installed with a span (length) of 7 m. It can be confirmed through structural calculation that when a distributed load of 1 kN per square meter is applied to the unit structure material 100, the maximum deflection is 14 mm or less, which can ensure very strong structural performance.

[0084] As described above, the unit structural material 100 according to the present invention has material properties consisting of a composite material of an upper plate 110 and a lower plate 120 made of a metal material and a core layer 130 made of a non-foamed polymer, and has a plate reinforcement structure of a bent portion 100B included therein, which can achieve ultra-light weight and significantly superior structural performance.

[0085] Specifically, compared with steel plate structural materials mainly used in the shipbuilding field, the unit structural material 100 made of the composite material according to the present invention can achieve equivalent structural performance with a weight of about 50 to 60%, and compared with reinforced concrete structures mainly used in the construction field, it can achieve equivalent structural performance with a weight of about 15 to 25%.

[0086] In addition, of course, the multi-structure material 200 and the overlapping structural material 300 formed by connecting and overlapping a plurality of high-performance unit structural materials 100 as described above can also have stronger structural characteristics.

[0087] More preferably, the unit structural material 100 according to the present invention can be manufactured to meet the minimum L / 480 deflection standard. Here, "L" refers to the length (span) of the unit structural material 100, and when the central portion of the unit structural material 100 sags no more than 1 / 480 of the total length of the unit structural material 100, it is deemed to meet the standard. As described above, the unit structural material 100 according to the present invention is manufactured to a length (span) of 7m, and the deflection that occurs when both ends are fixed is less than 14mm, and its value is 7,000 / 480≒14.583 (mm) or less, which shows that the above-mentioned L / 480 deflection standard is met.

[0088] In order to meet the above-mentioned deflection standard, the structural performance of the unit structural material 100 can be achieved by adjusting the height or shape of the curved portion 100B. In addition, by providing a certain level of bonding strength between the upper plate 110, the lower plate 120 and the core layer 130, the structural performance of the unit structural material 100 can be helped to be achieved. Specifically, the non-foamed polymer constituting the core layer 130 has its own adhesive force, and as described below, during the solidification process of the liquid non-foamed polymer stock solution, the surfaces in contact with the upper plate 110 and the lower plate 120 will be airtightly bonded, and the present invention can provide a bonding strength of 1 to 10 MPa, more preferably 6 MPa, between the upper plate 110 and the core layer 130 and between the lower plate 120 and the core layer 130.

[0089] like Figure 2 In the embodiment shown in (g), even in the form in which the bent portion 100B is constituted by a separate metal angle 140, the metal angle 140 can have sufficient strength simply by being inserted and bonded between the upper plate 110 and the lower plate 120 without welding.

[0090] The metal angle bar 140 is inserted between the upper plate 110 and the lower plate 120 so that the contacting surfaces are bonded by the adhesive, and the surface contacting the core layer 130 may also be bonded by the self-adhesive force of the non-foamed polymer forming the core layer 130. At this time, in order to prevent the contacting surfaces from peeling off, as described above, an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, may be provided between the upper plate 110 and the lower plate 120 and the metal angle bar 140.

[0091] At the same time, when constructing the core layer 130 of the unit 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 in addition. In this case, since a high-performance thermal insulation material with low thermal conductivity is additionally provided between the upper plate 110 and the lower plate 120, excellent thermal insulation performance can be achieved.

[0092] More specifically, the core layer 130 can be formed by placing a non-foamed polymer and a high-performance thermal insulation material with a thermal conductivity of less than 0.02W / mK between the upper plate 110 and the lower plate 120. For example, when the core layer 130 further includes a vacuum thermal insulation material (VIP: Vacuum Insulation Pane) with a thermal conductivity of 0.004W / mK, the total thickness of the unit structure 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 it is light in weight, it can achieve superior structural performance.

[0093] 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 due to the airtight structure of the non-foamed polymer, the gas entering and exiting the vacuum insulation material is completely blocked, which can achieve the effect of almost semi-permanently extending the life of the vacuum insulation material.

[0094] When the core layer 130 is composed only of a non-foamed polymer, the advantage is that the manufacturing thickness of the unit structure material 100 can be optimized to a very thin thickness. When the non-foamed polymer and a high-performance thermal insulation material such as a vacuum thermal insulation material are included, the manufacturing of the unit structure material 100 is simpler (because the non-foamed polymer stock solution can be applied to the surface of the high-performance thermal insulation material and used like an adhesive) and excellent thermal insulation performance can be achieved. Therefore, the advantages of each method can be considered, and when forming the core layer 130 of the unit structure material 100 according to the present invention, it is selected and applied whether to use the non-foamed polymer alone or in combination with the high-performance thermal insulation material.

[0095] For reference, if the core layer 130 is composed only of high-performance thermal insulation material, the bonding strength with the upper plate 110 and the lower plate 120 is weak, making it difficult to ensure sufficient structural performance. Only when the non-foamed polymer surrounding the high-performance thermal insulation material is firmly fixed between the upper plate 110 and the lower plate 120 through bonding, can the unit structural material 100 of the present invention obtain satisfactory structural performance.

[0096] B. Method for manufacturing unit structure material

[0097] Below, refer to Figures 3 to 6 , a specific method for manufacturing the unit structure material 100 according to the present invention is described.

[0098] The thickness of the plate reinforcement material used in ships varies from 6 to 30 mm, but a thin thickness of about 6 to 15 mm is generally used. When the composite material structure of the non-foamed polymer and metal proposed in the present invention is used instead, the upper plate 110 and the lower plate 120 can be made of a metal sheet with a thickness of 1 to 3 mm, and the thickness of the non-foamed polymer constituting the core layer 130 can be formed into a very thin structure of about 5 to 15 mm.

[0099] However, it is actually difficult to form such a thin thickness of non-foamed polymer structure. This is because non-foamed polymer is basically viscous, so if the space to be filled is too narrow, it will produce a lot of friction resistance when injecting the stock liquid, making it difficult to spread evenly in the space. Considering the manufacturing characteristics between metal and non-foamed polymer, some classification rules that stipulate the basic performance and structural requirements of ships recommend that the thickness of the core material made of non-foamed polymer be formed to be 15mm or more. If it is not complied with, it shall be approved separately.

[0100] The manufacturing method described below relates to the case where the core layer 130 of the unit 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 130 made of a non-foamed polymer is difficult to form a thinner thickness, and more preferably, a method is proposed in which even if the core layer 130 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 130.

[0101] 1) First manufacturing method

[0102] Reference Figure 3 The flow of a first method for manufacturing the unit structural material 100 according to the present invention will be described.

[0103] First, with the upper plate 110 turned over, a liquid non-foaming polymer stock solution S is poured into the space formed by the flat portion and the edge portion of the upper plate 110. At this time, the amount of the injected non-foaming polymer stock solution S is about 2% more than the amount that can fill the space formed between the upper plate 110 and the lower plate 120 when the lower plate 120 is covered later (i.e., the amount corresponding to the volume occupied by the actual core layer).

[0104] Then, the lower plate 120 is introduced from above and pressed downward while the non-foamed polymer stock solution S is poured into the space of the upper plate 110. The lower plate 120 may be pressurized using a hydraulic device or the like until a predetermined gap is reached between the lower plate 120 and the upper plate 110. At this time, in order to maintain the gap between the upper plate 110 and the lower plate 120 at a designed thin thickness, a separate spacer may be additionally placed between the upper plate 110 and the lower plate 120.

[0105] The non-foamed polymer stock solution S filled in the lower part of the space of the upper plate 110 penetrates into the vertical spaces at both side edges under the pressure of the lower plate 120, that is, into the space between the upper plate 110 and the lower plate 120 formed in the vertical direction. At this time, since the filling amount of the non-foamed polymer stock solution S is greater than the volume occupied by the actual core layer 130, the excess amount can be pushed out and discharged.

[0106] The non-foamed polymer stock solution S uniformly filled between the upper plate 110 and the lower plate 120, including the amount filled into the above-mentioned vertical space, cures over time to form the core layer 130. Due to the formation of the core layer 130, the manufacturing of the unit structural material 100 according to the present invention is completed.

[0107] The above-mentioned first manufacturing method is a method of injecting the non-foamed polymer stock solution S into an open space instead of a closed space. This manufacturing method can overcome the frictional resistance generated when injecting the non-foamed polymer solution S by pressurization, form a thin-thickness plate reinforcement structure, and has the advantage that the operation can be carried out while visually inspecting whether the non-foamed polymer solution S is properly filled in the entire structure corresponding to the core layer 130.

[0108] On the other hand, the above-mentioned first manufacturing method is an open cavity method. As the operation progresses, an area where the non-foamed polymer stock solution S comes into contact with air will be generated, and thus bubbles may be generated. As described above, these bubbles can be removed by injecting the non-foamed polymer solution S in an amount at least 2% more than the volume corresponding to the core layer 130 and pushing out the excess from the structural material.

[0109] For reference, Figure 3 shows the most basic form of the unit structural material 100 according to the present invention ( Figure 1 and Figure 2 (the form shown in (a)) as an example. If the upper plate 110 or the lower plate 120 is not bent and is only formed in the horizontal direction, a temporary dam can be used to temporarily form the plate into a "匚" shape, and the temporary dam can be removed after the non-foamed polymer stock solution S cures and the core layer 130 is completed to apply this manufacturing method.

[0110] 2) Second manufacturing method

[0111] Referring to Figure 4 According to the present invention, the second manufacturing method of the unit structural material 100 is a method of forming a closed space between the upper plate 110 and the lower plate 120 and injecting the non-foamed polymer stock solution into this closed space, wherein the injection tube for injecting the non-foamed polymer stock solution is divided into a plurality of small tubes instead of one.

[0112] Generally, when two organic compound liquids such as ISO and polyol are mixed, a non-foaming polymer undergoes a chemical reaction and starts to cure from this moment. The time for the chemical reaction to occur is only a few minutes, so the injection of the non-foaming polymer stock solution must be completed within a few minutes. Additionally, due to the viscosity of the non-foaming polymer stock solution itself, it may be difficult to spread evenly within a few minutes.

[0113] This manufacturing method aims to solve the above-mentioned process difficulties. By dividing the injection tube for injecting the non-foaming polymer stock solution into multiple small tubes and placing them closely in the space where the core layer 130 is to be formed, the non-foaming polymer stock solution can be injected quickly and evenly into the sealed space between the upper plate 110 and the lower plate 120.

[0114] In this manufacturing method, if the upper plate 110 or the lower plate 120 does not have a "C" shape, a temporary dam can be used to temporarily make the shape of the relevant plate into a "C" shape and the operation can continue, which is the same as the above-mentioned first manufacturing method. Of course, it can also be applied to the manufacturing method described below.

[0115] In addition, as Figure 2 (h) shows, when the unit structural material 100 according to the present invention includes a finishing component 150, the finishing component 150 can replace the function of the temporary dam.

[0116] 3) Third manufacturing method

[0117] Referring to Figure 5 , the third manufacturing method of the unit structural material 100 according to the present invention is a method of forming a sealed space between the upper plate 110 and the lower plate 120 and injecting a non-foaming polymer stock solution into this sealed space, wherein, when injecting, air is removed from the sealed space using a vacuum pump VP.

[0118] More specifically, after forming a sealed space between the upper plate 110 and the lower plate 120, an injection tube is inserted on one side to inject the non-foaming polymer stock solution, and a vacuum pump VP is used on the other side to suck in the air in the sealed space.

[0119] According to this third manufacturing method, there are the following advantages: Due to the pressure difference inside and outside the sealed space, not only can the frictional resistance during the injection of the non-foaming polymer stock solution be overcome, but also a thin thickness can be injected. Moreover, due to the suction force of the vacuum pump VP, rapid injection can be achieved.

[0120] 4) Fourth manufacturing method

[0121] The upper plate 110 and the lower plate 120 used to manufacture the unit structure material 100 according to the present invention use metal plates that are much thinner than steel plates used for general ships. Therefore, there is an inconvenience in the construction method, that is, since the thickness of the metal plate is too thin, it is difficult to maintain the shape and flatness of the plate before or during the filling of the core material (non-foamed polymer).

[0122] Conventionally, in the process of filling the core between the two plates, a spacer is used to maintain the shape (or maintain the gap). In addition, when a non-foamed polymer is used as the core, it has the characteristic of slightly expanding during the curing process, so the upper plate may be 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 lower 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.

[0123] 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 130 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.

[0124] In addition, the unit structural material 100 according to the present invention includes a structure that is bent downward. In this case, it is difficult to keep the bending angle constant due to the nature that the upper plate 110 and the lower plate 120 are made of thin plates.

[0125] The fourth manufacturing method of the unit structural material 100 of the present invention is proposed to solve the difficulties in the above-mentioned process. If the first to third manufacturing methods mentioned above are methods related to filling non-foamed polymers, the fourth manufacturing method can be regarded as a method related to maintaining the overall shape and flatness of the structural material before and during the injection of non-foamed polymers.

[0126] Specifically, Figure 6 As shown, in a state where the space between the upper plate 110 and the lower plate 120 is filled with a non-foaming polymer stock solution S, when a magnet M is placed on the upper portion of the lower plate 120, due to the magnetic field generated by the magnet M, the upper portion of the lower plate 120 is in close contact with the magnet M, thereby maintaining a flat state.

[0127] For reference, in this embodiment, since the manufacturing process of the unit structure material 100 is carried out with the upper plate 110 and the lower plate 120 turned over, the magnet M is placed on the upper surface of the lower plate 120. If the upper plate 110 is set at the upper part for the manufacturing process, the magnet M needs to be placed on the upper surface of the upper plate 110. That is, there is no need to consider the flatness problem of the plate placed on the floor, and the magnet M needs to be placed on the upper surface of the plate arranged on the upper side of the non-foamed polymer stock solution S.

[0128] Here, the magnet M can be understood as a concept including all magnetic bodies capable of generating a force to attract metals, including electromagnets. The size of the magnet M does not need to correspond to the entire area of the plate that needs to maintain flatness. 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. When only one magnet M is used, it is preferably placed at the central part of the plate.

[0129] In addition, the magnets M can also be placed on the sides of the upper plate 110 and the lower plate 120 that are not only horizontally placed but also vertically erected according to the same principle to maintain flatness and obtain the required bending angle.

[0130] For convenience, only the placement positions of the magnets M are briefly shown in the figure, but the magnets M can be configured to be included in the work jig or surface plate that fixes the positions of the upper plate 110 and the lower plate 120. In this case, even if no separate clamping part is provided in the work jig, the incidental effect of easily clamping the upper plate 110 and the lower plate 120 made of metal plates by the magnetic force can be enjoyed.

[0131] When applying this manufacturing method, if there is no vertically erected part on the upper plate 110 and the lower plate 120 (that is, if it is not in the shape of "匚"), the magnet M may not be placed on this part.

[0132] In addition, this manufacturing method can be implemented using a vacuum adsorption device instead of the magnet M. Specifically, the vacuum adsorption device adsorbs specific parts on the plate that need to maintain flatness and applies a pulling force, thereby maintaining the shape of the structural material and maintaining flatness.

[0133] Similar to the case of applying the magnet M, the vacuum adsorption device can simply perform the function of maintaining flatness by providing an adsorption force to a part of the plate instead of the entire area. Preferably, the central part of the plate that needs to maintain flatness is adsorbed. In addition, multiple vacuum adsorption devices can also be applied to one plate.

[0134] The unit structure material 100 according to the present invention manufactured by applying the fourth manufacturing method 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 lower plate 120 can be greatly reduced, which has the effect of reducing manufacturing time and cost.

[0135] At the same time, two or more of the above-mentioned first to fourth manufacturing methods can be applied in parallel. For example, when the first manufacturing method is performed in a confined space instead of an open cavity, the vacuum pump of the third manufacturing method can be used to remove air from the confined space, and, as with the second manufacturing method, the vacuum pump of the third manufacturing method can be applied while injecting the non-foamed polymer stock solution using multiple injection tubes. In addition, the fourth manufacturing method is a method for maintaining the shape and flatness of the structural material, and therefore can be used in parallel with any other manufacturing method.

[0136] 2. Second embodiment - multi-structure material

[0137] A. Structure of multi-structured materials

[0138] A multi-structure material 200 as another embodiment of the lightweight structure according to the present invention may be constructed by connecting a plurality of the above-mentioned unit structure materials 100. In practice, in order to form a floor, ceiling, and wall structure of a building or a ship, it is necessary to apply the multi-structure material 200 which ensures a sufficient area by continuously arranging a plurality of unit structure materials 100.

[0139] Reference Figure 7 and Figure 8 The multi-structure material 200 according to the present invention can be basically manufactured by structurally combining a plurality of unit structural members 100 in the width direction. At this time, the unit structural members 100 adjacent to each other can be connected by welding or bolting the opposite bent portions 100B.

[0140] More specifically, if Figure 7 As shown, when the outer side surfaces of the opposite bent portions 100B are formed of metal, welding or bolting can be freely applied, such as Figure 8 As shown, when the outer side surface of the core layer 130 constituting the bent portion 100B is exposed, it may be more appropriate to apply bolt connection.

[0141] The multi-structure material 200 formed by combining a plurality of unit structure materials 100 can be located anywhere above or below the existing concrete slab. That is, the multi-structure material 200 according to the present invention can be applied anywhere in the floor or ceiling structure of a building, and can also be applied to the wall structure of a building if necessary.

[0142] At the same time, the unit structural material 100 according to the present invention can also be structurally connected to the wall only at both ends along the length direction to form a floor or ceiling structure, rather than directly combining the individual modules. Specifically, in the space to be formed with a floor or ceiling structure, only the two ends of a plurality of unit structural materials 100 along the length direction are fixed to the wall, and along the width direction, adjacent unit structural materials 100 can be configured to be in close contact or separated by a predetermined interval. In addition, a base plate structure or a ceiling structure can be formed by constructing a floor finishing material on the upper part of a plurality of unit structural materials 100 arranged in a row or by constructing a ceiling finishing material on the lower part.

[0143] That is, the multi-structure material 200 according to the present invention does not necessarily require bonding between the unit structure materials 100. Even if the unit structure materials 100 constituting the multi-structure material 200 are in close contact or spaced apart at predetermined intervals, a floor or ceiling structure without structural problems can be formed by performing finishing work in the space between them.

[0144] In addition, in the structure in which the unit structural materials 100 are not bonded to each other in the width direction as described above, when a floor impact occurs, the entire floor does not vibrate, and only the individual unit structural materials 100 that are impacted vibrate, thereby having the advantage of locally limiting the propagation of the impact. In addition, when an individual unit structural material 100 vibrates, friction with other unit structural materials 100 adjacent thereto can be avoided or minimized, so vibration reduction / noise reduction performance can be expected.

[0145] B. Application examples and effects of multi-structure materials

[0146] Next, specific application examples and effects of the multi-element structural material 200 according to the present invention are described.

[0147] 1) Floor structure of the building (double floor structure)

[0148] The multi-structure material 200 according to the present invention can be generally applied to a double-layer floor structure of a building. Hereinafter, the implementation of the double-layer floor structure using the multi-structure material 200 according to the present invention will be described in detail.

[0149] Reference Fig. 9 , the two ends of the multi-structure material 200 according to the present invention along the length direction can be fixed to the upper building wall. At this time, the placement of the multi-structure material 200 needs to leave a small gap with the concrete slab constituting the upper floor to form a double-layer floor structure, so as to significantly improve the noise reduction performance between floors.

[0150] Generally, multi-story buildings such as apartments, houses, office buildings, and skyscrapers are separated from the upper and lower floors by concrete slabs, with the upper floors using concrete slabs as floors and the lower floors using concrete slabs as ceilings.

[0151] Traditionally, floor construction is done on a concrete slab so that it can be used as the floor for the upper level, specifically, insulation and hot water pipes are installed on the concrete slab, and finally mortar construction is done on top of it to form a floor that can actually be walked on.

[0152] However, the conventional floor structure as described above has a serious problem of inter-floor noise because the impact or friction applied to the floor is transmitted to the lower floor through the concrete slab. Although people are trying to solve the problem of inter-floor noise by implementing a double-layer floor structure, as mentioned above, the existing double-layer floor structure still has the problem of transmitting inter-floor noise through the bracket supporting the upper floor on the concrete slab.

[0153] However, when the upper floor is formed with the multi-structure material 200 according to the present invention to realize a double-layer floor structure, even if each unit structural material 100 constituting the multi-structure material 200 is configured as a long-span structure, the deflection is very limited. Therefore, sufficient structural performance can be ensured only by fixing both ends in the length direction of the multi-structure material 200 to the building wall. Therefore, there is no need to install a separate bracket between the concrete slab and the upper floor, and the upper floor and the concrete slab are structurally separated, so that a double-layer floor structure that is very effective in reducing inter-floor noise can be realized.

[0154] Reference Fig. 9 , the effect of reducing inter-floor noise due to application of the multi-structure material 200 according to the present invention will be described in more detail.

[0155] Generally speaking, inter-floor noise can be divided into two types: first, the noise that is transmitted primarily through the floor structure by the weight or friction impact sound generated by the upper floor; and second, the noise that is transmitted secondarily from the upper floor through the wall. When a double-layer floor structure is implemented using the multi-structure material 200 according to the present invention, the impact sound generated on the multi-structure material 200 side 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 as sound energy rather than direct vibration transmission, the total amount of energy transmitted to the lower floor can be greatly reduced.

[0156] In addition, the vibration transmitted from the upper multi-structure material 200 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 vibration and sound energy applied to the lower ceiling finishing material can be greatly reduced.

[0157] In addition, the present invention proposes various buffer connection structures between the multi-structure material 200 and the wall, so as to more effectively block the propagation of noise through the wall when the multi-structure material 200 is connected to the building wall, and through this structure, the above-mentioned inter-floor noise is minimized. Figures 10 to 13 , the connection structures applicable to the multi-structure material 200 according to the present invention and the wall will be understood respectively.

[0158] First, refer to Fig.10 Understand the first wall connection structure. In the first wall connection structure, the anchor pad 211 is installed on the building wall, and the metal plate 212 for fastening to the anchor pad 211 is fixed to both ends along the length direction of the multi-structure material 200 by welding. The anchor pad 211 and the metal plate 212 are fixedly connected by bolts, and at this time, a shock-absorbing buffer material can be provided between the anchor pad 211 and the metal plate 212 to mitigate the impact transmitted from the multi-structure material 200 to the wall.

[0159] At the same time, when the multi-structural material 200 according to the present invention is fixed to a wall, it is not necessary to fix all of the multiple unit structural materials 100 constituting the multi-structural material 200 to the wall. As long as sufficient structural performance for the design load can be ensured, only a part of the multiple unit structural materials 100 can be fixed to the wall.

[0160] Next, refer to Fig.11 Understand 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 piece (or the L-shaped angle piece is combined to the lower end of the anchor pad 221), and the lower end of the metal plate 222 can be inserted into the space formed by the lower L-shaped angle piece of the anchor pad 221 and supported while preventing separation in the horizontal direction. The upper end of the metal plate 222 can be fixed to the anchor pad 221 or the wall by bolt connection.

[0161] 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 multi-structure material 200 to the wall.

[0162] The connection structure is such that the lower portion of the metal plate 222 is accommodated and supported by simply inserting it into the space without mechanically fastening it with a separate component, and only the upper end portion is fastened by bolts. Since the metal plate 222 only needs to be placed on the anchor pad 221 including the L-shaped angle piece and the upper end portion is fixed to the wall, the on-site workability is very simple and a structurally strong connection can be achieved.

[0163] Next, refer to Fig.12Understand 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 multi-structure material 200 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 multi-structure material 200 to the wall.

[0164] In this 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 .

[0165] if Fig.11 The second wall connection structure shown is a structure that does not constrain the lower end of the metal plate 222 and allows slight movement within a predetermined range. Fig.12 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.

[0166] at last, Fig.13 The fourth wall connection structure shown is a way of connecting the multi-structure member 200 instead of directly connecting it to the building wall through the vibration reduction device 241. Here, the vibration reduction device 241 can be a hydraulic device or a spring device that can absorb vibration in the up and down directions.

[0167] When the fourth wall connection structure is applied, the vibration caused by the impact generated by the multi-structure material 200 is not transmitted to the wall. In addition, since the vibration transmitted from the multi-structure material 200 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.

[0168] In addition, although not shown in the drawings, in addition to the above-mentioned first to fourth wall connection structures, additional damping effects can be achieved by placing various buffer materials in the space between the multi-structural material 200 and the concrete slab to further reduce inter-floor noise.

[0169] When the multi-structure material 200 according to the present invention is used as a floor structure of a building, the following effects can be achieved.

[0170] (1) First, by adopting a double-layer floor structure, it has the effect of reducing noise between floors.

[0171] As described above, when the multi-structure material 200 according to the present invention is applied, a strong double-layer floor structure can be realized without a bracket, and thus the noise between floors can be significantly reduced.

[0172] (2) Second, it has the effect of simplifying the construction of heated kang ventilation.

[0173] As described above, the multi-structure material 200 according to the present invention has significantly excellent structural performance, so there is no need to perform ondol construction (heating construction) on the light floor to increase the structural strength like the existing double-layer floor structure. Therefore, when the multi-structure material 200 according to the present invention is installed on the existing concrete slab, it has the following advantages: the hot water pipe or cooling / heating pipe engineering required for the ondol construction can be conveniently performed on the existing concrete without the need for a separate ventilation mortar engineering.

[0174] 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 people can walk, it is necessary to carry out floor mortar work or install a separate dry ondol board before finishing the floor material construction. However, since the multi-structure material 200 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 board installation work that was previously performed, and since the finishing floor material construction can be directly carried out on the multi-structure material 200, the heated ondol ventilation project can be made simpler.

[0175] In addition, the structure that needs to be heated becomes lighter and simpler, which is also very beneficial in terms of thermal efficiency.

[0176] (3) Third, it has the effect of simplifying step engineering.

[0177] The manufacturing of the floor step structure of the bathroom or entrance is also very convenient. Usually, the floor of the bathroom or entrance is designed to have a step that is several tens of millimeters lower than other floors, and using traditional construction methods, a separate formwork operation or ventilation operation is required to form such a step. However, according to the present invention, all floors on the same level are manufactured to be flat, and the step construction only needs to be carried out on the multi-structure material 200, so the step construction can be simplified.

[0178] 2) Ceiling structure of the building

[0179] Reference Fig.14 It is also possible to install the multi-structure material 200 according to the present invention under a concrete slab and use it as a ceiling structure.

[0180] In this case, since the lower-layer ceiling finishing material can be directly attached to the lower side of the multi-structural material 200, a separate bracket project and carpentry project for attaching the ceiling finishing material are not required, which has the effect of simplifying the ceiling project.

[0181] 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 multi-structure material 200 according to the present invention, a modular construction method can also be applied through pre-outfitting.

[0182] Meanwhile, when the multi-structure material 200 according to the present invention is used as a ceiling structure, there is no need to consider the function of inter-floor noise, and thus it can also be connected to the building wall by simple mechanical fastening such as bolt connection. However, the present invention is not limited thereto, and of course, a buffer structure such as the above-mentioned first to fourth wall connection structures can be applied as needed.

[0183] 3) Ship structure

[0184] The multi-structure material 200 according to the present invention can be applied not only to buildings but also to the construction of decks of ships or floor structures of ship living areas, and can have the following effects when applied to ships.

[0185] (1) First, it has the effect of solving the existing welding thermal deformation problem.

[0186] As mentioned above, traditionally, the Fig.19 The steel plate structural material 10 shown forms a deck of a ship. In this case, since the plate reinforcing material 20 is welded under the steel plate structural material 10, a serious thermal deformation problem cannot be avoided.

[0187] In addition, if only the structural performance as a ship deck is generally considered, the thickness of the steel plate structural material 10 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, the thickness of the steel plate structural material 10 is increased to about 10 mm in the initial manufacturing. However, even if the thickness of the steel plate structural material 10 is increased, the problem of thermal deformation caused by the welding of the plate reinforcing material 20 still exists, and therefore, in most cases, a lot of time is invested in repair work by hot working after welding the plate reinforcing material 20.

[0188] However, in the lightweight structure according to the present invention, the bent portion 100B that functions as a plate reinforcement material is already included in the structure of the unit structural material 100. When this structure is adopted, welding is not required to attach 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 the steel plate structural material 10, which is still mainly used in the shipbuilding industry, can be fundamentally solved.

[0189] In addition, even when the multi-structure material 200 according to the present invention is manufactured by welding between unit structure materials 100, since welding is performed between the unit structure materials 100 that already have rigidity, the amount of thermal deformation of the entire plate can be greatly reduced.

[0190] The multi-structure material 200 according to the present invention is expected to be very useful in the shipbuilding industry, particularly when applied to the manufacture of car decks (Car-Decks) of car carriers (PCC: Pure Car Carrier), and is also effective in the formation of floor structures of ship living areas.

[0191] (2) Second, it has the effect of reducing the weight of the ship.

[0192] The unit structural material 100 composed of composite materials and the multi-structure material 200 made by combining them according to the present invention are about 40% to 50% lighter than existing steel plates, can achieve equivalent structural performance, and also make a great contribution to the lightweighting of ships.

[0193] 3. Third embodiment - overlapping structural materials

[0194] A. Structure of overlapping structural materials

[0195] Meanwhile, the overlapping structural material 300 as another embodiment of the lightweight structure according to the present invention may be formed by placing the above-mentioned multiple structural materials 200 in an overlapping manner.

[0196] Reference Fig.15 The overlapping structural material 300 according to the present invention can be formed in the form of multiple structural materials 200 stacked up and down, wherein the multiple structural material 200 is formed by connecting a plurality of unit structural materials 100.

[0197] When the overlapping structural material 300 according to the present invention is used as a floor, ceiling or wall structure, both ends along the length direction of the structure will be fixed, so there is no need for direct structural connection between the multiple structural materials 200 arranged above and below.

[0198] In addition, the overlapping structural material 300 according to the present invention may be configured to provide a predetermined gap between the multiple structural materials 200 that are opposite in the up-and-down directions, and if the structure is used as a double floor structure, the effect of reducing the noise factor between floors may be doubled.

[0199] B. Application examples and effects of overlapping structural materials

[0200] The overlapping structural material 300 according to the present invention can be used for various purposes similar to the above-mentioned multi-structure material 200. In particular, since the overlapping structural material 300 according to the present invention itself includes a double-layer floor structure, it can be preferably used as a floor structure of buildings and ships in order to expect an inter-floor noise reduction effect. However, the present invention is not limited thereto, and of course, it can also be used as a wall or roof structure of a building or a ship.

[0201] In addition, since the overlapping structural material 300 according to the present invention is formed by stacking the multiple structural materials 200 up and down, various additional functions can be easily added by pre-installing various devices in the space formed therebetween.

[0202] As a specific application example, refer to Fig.16 , by installing the heat insulating material I and the cooling / heating pipe P in the space between the upper and lower multi-structure materials 200 constituting the overlapped structural material 300, the ondol function can be easily added to the overlapped structural material 300. 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 the surrounding area of ​​the cooling / heating pipe P can leave space.

[0203] 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.

[0204] However, when the overlapping knot material 300 according to the present invention is applied, since the multi-structure material 200 arranged on the upper part performs a structural function, no separate mortar construction is required, so the construction of the heated kang structure and / or the floor cooling / heating structure can be carried out very conveniently and simply.

[0205] Also, see Fig.17 It is also possible to achieve fireproof performance of the floor by adding a fireproof material R between the multi-structure material 200 and the insulation material I disposed at the bottom without the need for a separate fireproof coating.

[0206] 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 certain load (for example, 3kN / m 2 ) or above, the lower part of the structural material is exposed to a heat source, and the deflection of the structural material is checked after a certain period of time (for example, 2 hours) to confirm the structural stability.

[0207] Conventional building structural materials are usually made of metal, which loses its structural performance when heated during fire resistance testing and exceeds a certain temperature. Therefore, in order to meet fire protection standards, subsequent work is being implemented to cover the lower part of the metal with fireproof materials.

[0208] However, if Fig.17 As shown, according to the structure of the present invention in which the fire-resistant material R is placed in advance inside the modularly manufactured overlapping structural material 300, even if the multi-structure material 200 arranged at the bottom loses its structural performance due to exposure to the heat source caused by the fire, the upper multi-structure material 200 protected by the fire-resistant material R can maintain its structural performance. Therefore, even if additional fire-resistant coating work is not performed as in the conventional method, 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.

[0209] Reference Fig.18 The overlapping structural material 300 according to the present invention, similar to the multi-structure material 200, can be fixed to the building wall at both ends along the length direction, and when the overlapping structural material 300 is used as a floor structure, it can be set to have a gap with the concrete slab constituting the upper floor.

[0210] At this time, the upper multi-structure material 200 and the lower multi-structure material 200 constituting the overlapping structural material 300 may be respectively connected to the building wall, and as described above, only a portion of the plurality of unit structural materials 100 constituting each multi-structure material 200 may be directly fixed to the wall.

[0211] In addition, when a double-layer floor structure is realized by using the overlapping structural material 300 according to the present invention, since the impact sound which is the direct cause of the inter-floor noise is generated from the upper multi-structure material 200, it is possible to realize the double-layer floor structure by applying the above-mentioned reference Figures 10 to 13 The first to fourth wall connection structures described connect the upper multi-structure material 200 to the building wall to achieve a buffering effect, and the lower multi-structure material 200 can be connected to the wall by simple mechanical fastening such as bolt connection.

[0212] When the overlapping structural material 300 according to the present invention is used as a floor structure of a building, the following effects may be achieved.

[0213] (1) First, it is possible to realize an ultra-light, large-span dry structure with significantly superior structural performance.

[0214] 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.

[0215] Although the weight of the overlapping structural material 300 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 construction method, 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 construction method, the structural performance is immediately reflected after installation, so the entire construction period can be significantly shortened.

[0216] (2) Second, since the overlapping structural material 300 itself includes a double-layer floor structure, a floor structure construction having an excellent inter-floor noise reduction effect can be performed. That is, a high-performance floor structure having an excellent inter-floor noise reduction effect can be realized only by its own structure without requiring a separate composite floor structural material or a vibration-absorbing device for inter-floor noise reduction.

[0217] (3) Thirdly, there is an advantage that various pipes or ceiling accessories can be pre-installed inside or below the overlapping structural material 300.

[0218] In particular, as previously referenced Fig.16 As described above, since the insulation material I and cooling / heating pipes P required for floor heating can be easily installed in the structure of the overlapping structural material 300 through pre-installation, a separate heating and ventilation project can be omitted, thereby greatly simplifying the entire construction project. In addition, the floor temperature will react faster to the temperature adjustment, and the structure that needs to be preheated will become lighter and simpler, which is also very beneficial in terms of thermal efficiency.

[0219] In addition, as previously referenced Fig.17 As described above, according to the structure in which the fireproofing material R is additionally arranged within the structure of the overlapping structural material 300, the self-fireproofing performance can be fully realized without a separate post-fireproofing treatment.

[0220] 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 lightweight structure made of composite material, characterized in that: Comprising: An upper plate, made of metal; A lower plate, arranged to be spaced apart from the upper plate at a predetermined interval and made of metal; And A core layer, formed between the upper plate and the lower plate and made of a non-foamed polymer, Further comprising: A multi-structural material, composed of a plurality of unit structural materials arranged continuously in the width direction, wherein, The unit structural material includes a "C"-shaped cross-sectional structure, which includes a bending structure that bends downward at both ends along the entire width direction of the structure.

2. The lightweight structure made of the composite material according to claim 1, characterized in that The unit structural material includes: A flat plate portion, formed in the horizontal direction; and A bending portion, bending downward from both ends of the flat plate portion.

3. The lightweight structure made of the composite material according to claim 2, characterized in that The bending portions of the adjacent unit structural materials are structurally joined by bolts or welding.

4. The lightweight structure made of the composite material according to claim 2, characterized in that The adjacent unit structural materials are arranged to be spaced apart at a predetermined interval, and the space between the adjacent unit structural materials is finished to form a floor, ceiling or wall.

5. The lightweight structure made of the composite material according to claim 3 or 4, characterized in that Both ends of the multi-structural material in the length direction are fixed to the wall of the building to form the floor structure or ceiling structure of the building.

6. The lightweight structure made of the composite material according to claim 5, characterized in that When forming the floor structure of the building, the multi-structural material is provided with a gap on the upper side of the concrete slab constituting the basic frame of the building to form a double-bottom floor structure.

7. The lightweight structure made of the composite material according to claim 6, characterized in that The connection part of the multi-structural material and the wall adopts a vibration-absorbing buffer structure, including a shock-absorbing buffer material, a spring or a hydraulic device.

8. The lightweight structure made of composite material according to claim 2, characterized in that: Comprising: An overlapping structural material, formed by overlapping the multi-structural materials up and down.

9. The lightweight structure made of the composite material according to claim 8, characterized in that A pair of the multi-structural materials are arranged in a direction where the bending portions face each other.

10. The lightweight structure made of the composite material according to claim 9, characterized in that The space between a pair of the multi-structural materials is pre-fitted with heat-insulating materials and heating / cooling pipes to be modularized.

11. The lightweight structure made of the composite material according to claim 10, characterized in that A fireproof material is additionally constructed between the heat-insulating material and the multi-structural material.

12. The lightweight structure made of the composite material according to claim 8, characterized in that Both ends of the overlapping structural material in the length direction are fixed to the wall of the building to form the floor structure or ceiling structure of the building.

13. The lightweight structure made of the composite material according to claim 12, characterized in that Both ends of each of the upper multi-structure material and the lower multi-structure material constituting the overlapping structural material in the length direction are fixed to the wall.

14. The lightweight structure made of composite material according to claim 13, characterized in that: When forming the floor structure of the building, a buffer structure capable of absorbing vibration is adopted at the connection part between the upper multi-structure material and the wall, including a shock-absorbing buffer material, a spring or a hydraulic device.

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