PREFABRICATED STRUCTURE FOR BUILDING

Abstract

TITLE: PREFABRICATED STRUCTURE FOR BUILDING This invention discloses a prefabricated structure of assembleable elements for the construction of buildings having one or more levels which comprises: structural wall panels, these structural wall elements comprising a cladding panel made of concrete and an insulating panel between the structural panel and the cladding panel, the structural wall panel and the cladding panel being structurally connected by means of interposed rigid separators which pass through the insulating panel; in which the structural wall panels are panels made of wood derivatives; the cladding panels have a front principal face, defined on a molding surface, smoother and more uniform than a rear principal face; and the rigid separators are vertical ribs having one end partially embedded in the concrete cladding panel.

Description

Title of the invention: PREFABRICATED STRUCTURE FOR BUILDING Scope of the invention

[0001] This invention relates to the field of prefabricated structures for buildings. State of the art

[0002] In the state of the art, prefabricated structures for buildings are known which, among other advantages, compared with traditional methods of building structure construction, reduce complexity, increase speed and decrease the cost of building structure construction.

[0003] In the prefabricated structures sector, structural wall panels are known, constituting a single level of the prefabricated structure, and are made of concrete. These concrete panels may have a coating or an inner layer of thermal insulation material, moisture insulation, etc.

[0004] These structural wall panels have the disadvantage of being quite heavy, which makes them difficult to handle. Furthermore, existing structural wall panels offer room for improvement in their insulation properties and for reducing their cost. This invention aims to improve these aspects.

[0005] Brief description of the invention

[0006] This invention relates to a prefabricated structure of assembleable elements for the construction of buildings with one or more levels, which comprises, in a manner known per se: - structural wall panels, each having a front principal face and a rear principal face, at least some of the structural wall panels being insulated structural wall panels which comprise a cladding panel made of concrete, having a rear principal face facing the rear principal face of the structural wall panel, and an insulating panel interposed between the two rear principal faces, the structural wall panel and the cladding panel being structurally connected by means of interposed rigid separators which pass through the insulating panel; - structural floor-slab panels;

[0007] wherein the structural wall panels, constituting a single level of the prefabricated structure, comprise lower supports resting on load-bearing elements of a lower part of the building structure, lateral connectors that connect at least some of these structural wall panels constituting a single level, and upper supports on which the panels rest structural floor-slab components constituting a single floor-slab of the prefabricated structure.

[0008] However, this invention also proposes, in a way not known, that: - structural wall panels are panels made of wood or wood derivatives; - the cladding panels have a main front face, defined on a molding surface, which is smoother and more uniform than the main rear face; - Rigid separators are vertical ribs with one end partially embedded in the concrete facing panel.

[0009] It will be understood that wood derivatives are manufactured by joining or fixing strands, particles, fibers, sheets or planks of wood, wood splinters, wood powder or other plant products such as bamboo, with adhesives to form a composite material. This type of wood is also known as solid wood, engineered wood, manufactured panel or engineered wood.

[0010] The most common types of wood derivatives are plywood, which is made from superimposed wood panels whose fibers have various orientations and are bonded by heat and pressure with durable, moisture-resistant adhesives. Laminated veneer lumber (LVL), which is similar to plywood but with the panels stacked with the fibers oriented in the same direction, oriented strand board (OSB), made from wood scales oriented in multiple directions, compressed and glued together, laminated wood fibers (LSL), similar to OSB but with the chips stacked in the same direction, and medium-density fiberboard, made from compressed and glued wood fibers or sawdust.Other types of engineered wood products are commonly known as Glulam, solid wood (EWP according to its English acronym) and cross-laminated timber (CLT according to its English acronym).

[0011] Thanks to this invention, the weight of the structural wall panel can be reduced because wood is lighter than concrete, and it increases the thermal insulation that this structural panel offers for a certain width, since wood is a better insulator than concrete. Furthermore, this invention reduces the cost and manufacturing time of the structural wall panel.

[0012] According to this invention, the concrete cladding panel can be reinforced with fibers, preferably polypropylene fibers.

[0013] According to this invention, the vertical ribs constituting the rigid separators can be metal trusses provided with two parallel stringers joined by means of bars, one of the stringers being embedded in the concrete of the cladding panel.

[0014] According to this invention, the vertical ribs constituting the rigid separators can be screwed onto the structural wall panel.

[0015] According to this invention, in at least one of the structural panels for insulated walls, the cladding panel can protrude above an upper edge of the corresponding structural wall panel, the upper seat of the structural wall panel remaining at a lower height than an upper edge of the cladding panel, so that the cladding panel hides, at least in part, the size of the structural floor-slab panel supported on the upper seat.

[0016] According to this invention, between the protruding part of the cladding panel and the structural floor-slab panel there may be a space filled with reinforced concrete forming a structural tie beam.

[0017] According to this invention, the structural linkage of the structural wall panels of the same level of the structure can support the lower courses of the structural wall panels of the next level of the structure.

[0018] According to this invention, the structural wall panels of a lower level of the structure can have the corresponding lower supports supported on prefabricated reinforced concrete beams supported on foundations or directly on crossbeams or foundation beams.

[0019] According to this invention, the structural panel can be at least twice as large as the cladding panel.

[0020] According to this invention, the structural wall panel can have a size of at least 10 cm.

[0021] Preferably, the structural panel has a thickness of at least 12 cm. Preferably, in addition, the structural panel has a thickness of at least 14 cm.

[0022] According to this invention, the structural wall panel may have a thickness equal to or less than 45 cm. Preferably, the structural wall panel has a thickness equal to or less than 35 cm. Preferably, in addition, the structural panel has a thickness equal to or less than 25 cm.

[0023] According to the invention, the cladding panel of the structural wall panel can have a size between 5 and 8 cm.

[0024] The described building structure is obtained by means of a manufacturing method which includes prefabricating several structural wall panels, prefabricating several structural floor-slab panels and transporting the structural wall panels and the structural floor-slab panels to a site location and assembling them together to produce the building structure.

[0025] The method further comprises, in a way not known, that the prefabrication of each insulating wall panel includes: - prefabricate an assembly by fixing the rigid separators on the main rear face of the structural wall panel; - pour the concrete, preferably reinforced with fiber, constituting the cladding panel, into an open mold leaving one face of the poured concrete exposed constituting the main rear face of the cladding panel; - by placing the first assembly and the exposed surface of poured concrete face to face, submerging at least part of each rigid separator in the poured concrete before it sets, causing the reinforcing fibers to interlock around the submerged portion of the rigid separators while it is submerged in the concrete; - the setting and demolding of the cladding panel.

[0026] Preferably, rigid, elongated, rib-like separators will be used, comprising elongated bars substantially parallel to the rear main surface of the cladding panel. The complete immersion of one of these elongated bars in the concrete greatly increases the interlocking of the concrete reinforcing fibers all around, surprisingly resulting in a significant improvement in the overall structural strength.

[0027] In this document, a smooth surface is understood to mean a surface without noticeable roughness, that is to say, one that has the appearance of being polished.

[0028] It will be understood that references to geometric positions, such as, for example, parallel, perpendicular, tangent, etc., admit deviations of up to +5° from the theoretical position defined by this nomenclature.

[0029] Other features of the invention will appear in the following detailed description of an example of implementation. Brief description of the figures

[0030] The preceding and other advantages and features will be better understood from the following detailed description of an example of implementation concerning the accompanying drawings, which are to be taken by way of illustration and not limitation, in which: - [Fig.1] schematically shows a structural wall panel of a prefabricated building structure according to this invention. - Fig. 2 schematically shows an initial step in the manufacture of a structural wall panel for a prefabricated structure according to this invention. - Fig. 3 schematically shows a formwork table for the manufacture of a structural wall panel for a prefabricated structure according to this invention. - Fig. 4 schematically shows a final stage in the manufacture of a structural wall panel for a prefabricated structure according to this invention.

[0031] Detailed description of an example implementation

[0032] The attached figures show illustrative, non-limiting examples of implementation of this invention.

[0033] In [Fig. 1], a schematic view of a structural wall panel 1 of a prefabricated structure according to this invention can be seen. This structural wall panel 1 defines a main front face and a main rear face and comprises a cladding panel 10 made of concrete, a structural panel 30 made of wood or wood derivatives, and an insulating panel 20 interposed between this cladding panel 10 and this structural panel 30.

[0034] This cladding panel 10, made of concrete, has a front principal face, defined on a molding surface, and a parallel rear principal face facing this front principal face. Because it is defined on a molding surface, this front face is smoother and more uniform than the rear principal face, thus providing it with a better surface finish. This allows the front principal face of the cladding panel 10 to be used in situations where a proper surface finish is important, for example, when the structural panel 1 is to be used as an exterior wall of a building, leaving the concrete of the cladding panel 10 exposed. This also applies even when the front principal face of the cladding panel 10 is not to be left exposed, i.e., when it is to be painted, covered, etc.A better surface finish makes it easier to perform the subsequent treatment that one wants to give to this main anterior face.

[0035] The cladding panel 10 of the implementation example of the structural panel 1 shown in [Fig.1] is made of white concrete mixed with polypropylene fibers.

[0036] The structural panel 30 made of wood derivatives increases the thermal insulation that the structural panel 1 offers for a certain width because of the insulating properties of wood, in addition to reducing the weight of this structural panel 1 compared with an equivalent structural panel made of concrete.

[0037] In the embodiment shown, the insulating panel 20, interposed between the cladding panel 10 and the structural panel 30, is a rigid polyisocyanurate (PIR) foam panel coated with an aluminum vapor barrier on its two main faces. However, in other embodiments, any other type of insulating panel may be used whose mechanical and chemical properties make it suitable for use in structural wall panels.

[0038] In this embodiment, the structural panel 30 is made of a cross-laminated fir board; that is, the structural panel 30 comprises a plurality of fir wood boards glued in longitudinal and transverse layers so as to reduce the stresses that the individual boards of the structural panel 30 must withstand. This structural panel 30 offers good thermal and acoustic insulation, in addition to being able to withstand high load values. In other embodiments, the structural panel 30 can be made of another type of conifer or of any other type of engineered wood.

[0039] To join the cladding panel 10, the insulation panel 20, and the structural panel 30, the structural wall panel 1 includes at least one connector 40. Preferably, this connector is fixed at one end to the structural panel 30, with the opposite end remaining embedded in the concrete cladding panel 10. Even though the insulation panel 20 remains fixed due to the confinement between the cladding panel 10 and the structural panel 30, the additional connector 40 may include means for fixing it to this insulation panel 20, thus increasing the connection of the various elements that constitute the structural wall panel 1.

[0040] Although its presentation has been omitted, the structural wall panel 1 shown may, where appropriate, include lateral connectors for connecting different structural wall panels 1 together, as well as lower supports for being supported on load-bearing elements of a lower part of the building structure and upper supports for supporting the structural floor-slab panels (not shown) constituting the same floor-slab of the prefabricated structure that is the subject of this invention.

[0041] The structural panel 30 can have a thickness of 10 to 20 cm. The cladding panel 10 can have a thickness of between 5 and 8 cm. The insulating panel 20 can have a thickness of 5 to 15 cm. Therefore, the structural wall panel 1 can have a thickness of 20 to 43 cm.

[0042] Figures 2 to 4 illustrate different stages of the manufacturing method of the structural wall panel 1 shown in [Fig.1].

[0043] In an initial step of manufacturing the structural panel 1, illustrated in [Fig. 2], the insulating panel 20 is placed on the wooden structural panel 30. In addition, the connector 40 is also placed on the face of the structural panel 30 against which the insulating panel 20 rests, and this connector 40 is fixed to the structural panel 30. This connection is preferably made using screws or similar fasteners, although any other type of connector that provides an equivalent fixing may be used.

[0044] As can be seen, after placing at least one connector 40 and the insulating panel 20 in the structural panel 30, this connector 40 protrudes from the insulating panel 20, by allowing that, in a later stage of the manufacture of the structural wall panel 1, part of this connector 40 remains embedded in the cladding panel 10.

[0045] Figure 3 illustrates an intermediate step in the manufacture or construction of the structural wall panel 1 of this invention. In this intermediate step, architectural or structural concrete is poured onto a formwork table 50. This concrete will constitute the facing panel 10 of the structural panel 1.

[0046] In this example of implementation, the concrete poured onto the formwork table 50 includes polypropylene fibers, although in other implementations other types of additives may be used and even the use of additives which improve the properties of the concrete may be omitted.

[0047] Figure 4 illustrates a final step in the manufacture or construction of the structural wall panel 1, which forms part of the prefabricated building structure according to this invention. In this final step, the assembly formed by the structural panel 30, the insulating panel 20, and the connector 40, shown in Figure 2, is positioned above the formwork table 50, such that the rear main face of the cladding panel 10 coincides with the front main face of the insulating panel 20, and such that one end of the connector 40 remains embedded in the fresh concrete on the formwork table 50, which will constitute the cladding panel 10.

[0048] When all the elements are in position, the concrete of the formwork table 50 is allowed to set until it forms the cladding panel 10. As soon as the cladding panel 10 has set, it can be demolded.

[0049] As defined on a molding surface, in this case the formwork table 50, the main front face of the cladding panel 10 and, consequently, of the structural wall panel 1, has a smooth surface having a good surface finish and good dimensional tolerance.

[0050] As soon as the structural wall panel 1 has been made, it is already ready to be stored and / or transported to the location where it will be installed as part of the prefabricated structure of a building.

Claims

Claims

1. A prefabricated structure of assemblable elements for the construction of buildings having one or more levels which comprises: - structural wall panels (30), each having a front main face and having a rear main face, at least some of the structural wall panels (30) being insulated structural wall panels (30) which comprise a cladding panel (10) made of concrete, having a rear main face facing the rear main face of the structural wall panel (30), and an insulating panel (20) interposed between the two rear main faces, the structural wall panel (30) and the cladding panel (10) being structurally connected by means of interposed rigid separators which pass through the insulating panel (20); - structural floor-slab panels;where the structural panels (30) for wall, constituting the same level of the prefabricated structure, comprise lower courses supported on load-bearing elements of a lower part of the structure of the building, lateral connectors which connect together at least some of these structural panels (30) for wall constituting the same level, and upper courses where the structural floor-slab panels constituting the same floor-slab of the prefabricated structure rest, characterized in that the structural panels (30) for wall are panels made of wood derivatives; the cladding panels (10) have a front main face, defined on a molding surface, smoother and more uniform than the rear main face; the rigid separators are vertical ribs having one end partially embedded in the concrete cladding panel (10).;

2. The prefabricated structure, according to claim 1, wherein the concrete cladding panel (10) is reinforced with fibers, preferably polypropylene fibers.

3. The prefabricated structure, according to claim 1 or 2, wherein the vertical ribs constituting the separators Rigid trusses are metal trusses provided with two parallel stringers joined by means of bars, one of the stringers being embedded in the concrete of the cladding panel (10).

4. The prefabricated structure, according to claim 3, wherein the vertical ribs constituting the rigid separators are screwed to the structural wall panel (30).

5. The prefabricated structure, according to any preceding claim, wherein at least one of the insulated structural wall panels, the cladding panel (10) projects, together with the insulation above an upper edge of the corresponding structural wall panel (30), the upper course of the structural wall panel (30) remaining at a lower height than an upper edge of the cladding panel (10), such that the cladding panel (10) conceals, at least in part, the thickness of the structural floor-slab panel supported on the upper course.

6. The prefabricated structure, according to claim 5, wherein between the projecting portion of the cladding panel (10) and the structural floor-slab panel there is a space filled with reinforced concrete which forms a structural chain.

7. The prefabricated structure, according to claim 6, wherein the structural chaining of the structural wall panels of the same level of the structure supports the lower courses of the structural wall panels of the next level of the structure.

8. The prefabricated structure according to any preceding claim, wherein the structural wall panels of a lower level of the structure may have corresponding lower courses supported on prefabricated reinforced concrete beams supported on foundations.

9. The prefabricated structure according to any preceding claim, wherein the structural wall panel (30) is at least twice as thick as the cladding panel (10).

10. The prefabricated structure, according to claim 9, wherein the structural wall panel (30) has a thickness of at least 10 cm.

11. The prefabricated structure, according to claim 10, wherein the structural wall panel (30) has a thickness of at least 12 cm.

12. The prefabricated structure, according to claim 10 or 11, wherein the cladding panel (10) of the structural wall panel (30) has a thickness of between 5 and 8 cm.

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