Lightweight structure made of composite material

Abstract

An upper plate made of a metal material; a lower plate made of a metal material spaced apart from the upper plate at a predetermined interval; and a core layer formed between the upper plate and the lower plate and made of a non-foamed polymer, including a bending structure in which both ends along the width direction of the overall structure are bent downward, and a multi-structural material is disclosed which includes a unit structural material having a "C"-shaped cross-sectional structure and is configured by arranging a large number of the unit structural materials continuously in the width direction, and is a lightweight structure made of a composite material.

Description

Technical Field

[0001] The present invention relates to a lightweight structure made of composite materials, and more particularly to a lightweight structure for floors, ceilings, and walls based on composite materials that is ultra-lightweight yet structurally high-performance and can be used in various ways in the fields of ships and construction.

Background Art

[0002] The most basic floor work for structures such as buildings and ships is one of the most important works. To form the floor of a structure, reinforced concrete is mainly used in buildings, and in the case of ships, structural materials composed of steel plates and plate reinforcements are often used.

[0003] The floors of structures have numerous problems in terms of construction methods and performance, among which the problem of impact noise between floors (noise trouble in Japan) is particularly emphasized. Ship floor materials are the most vulnerable in terms of impact noise between floors due to their characteristics of being composed only of metal, and reinforced concrete, which is a building floor material, has excellent performance especially in terms of impact noise between floors. However, at present, it is difficult to completely block impact noise between floors, which has caused serious social problems, and in particular, weight impact noise, which is structural noise caused by the impact of heavy objects, is regarded as the most significant problem.

[0004] In addition, the most significant reason for the occurrence of impact noise between floors in multi-story buildings is that the floor structure of the upper floor forms the ceiling structure of the lower floor. That is, since it is a method of sharing one concrete slab between two floors, it is fundamentally vulnerable to noise transmission through this. Of course, there is also structural noise transmitted through non-floor walls and noise transmitted through the gaps in buildings, but the transmission of structural noise due to the sharing of floor structures is known as the most significant cause of inducing impact noise between floors.

[0005] As methods for solving such problems of impact noise between floors, a wet floating floor structure (laminated floor structure) and a double floor structure are known.

[0006] The wet floating floor structure is a method of absorbing or blocking sound transmission by mixing and laminating various different materials inside and outside of a conventional concrete slab. However, the wet floating floor structure has a fundamental problem that it cannot completely block interlayer noise because noise and vibration are inevitably transmitted along the floor component layers connected in a laminated manner.

[0007] The double floor structure is a structure in which one more lightweight floor is provided on top of the concrete slab that supports the structural strength of a building. That is, it forms two floors and interposes an air layer therebetween to block sound transmission. However, in the conventional double floor structure, since the structural strength of the lightweight floor is not as strong as that of the concrete floor, it is required to provide several tens to several hundreds of supports for supporting between the lightweight floor and the concrete slab. Therefore, the transmission of noise / vibration through a large number of supports could not be ignored.

[0008] In addition, in the conventional double floor structure, the installation man-hours and costs are significantly increased. Moreover, when performing heating work for structural reinforcement on top of the lightweight floor, there are numerous problems such as problems with horizontal maintenance, problems in terms of constructability, and problems in terms of the finishing process.

Summary of the Invention

Problems to be Solved by the Invention

[0009] Nevertheless, in order to significantly reduce interlayer noise, a double floor structure that is structurally completely separated and each has sufficient strong structural performance is the most effective.

[0010] However, the problem is that it is realistically difficult to install a robust floor structure in duplicate using conventional materials and construction methods. In a typical multi-story building, rooms usually have a span (distance between walls) of about 3 to 8 m. To structurally install a robust double floor structure in such a space, structural reinforcement work at a level almost equivalent to conventional floor construction is required. Also, creating an SS with a double floor structure made of reinforced concrete from the very beginning of building construction is not realistic either economically or technically.

[0011] Even in the case of a ship, assuming that a secondary floor (upper floor) is made of conventional steel plate structural materials, satisfactory structural strength can only be obtained by densely welding plate reinforcement materials of at least 100 mm to a steel plate of at least 6 mm at intervals of 600 to 800 mm. At this time, however, a considerable amount of welding distortion occurs, so a considerable amount of subsequent fairing work is required to eliminate the thermal distortion. Also, just the self-weight of the secondary floor made of iron is considerable, so the economic efficiency is significantly reduced in terms of structural design.

[0012] Therefore, an object of the present invention is to provide a high-performance lightweight structure based on composite materials that can overcome the above-described technical limitations and can be innovatively used in the future in the fields of ships and construction.

[0013] In particular, the present invention aims to best solve the technical problem of enabling the easy implementation of a robust double floor structure that has been technically difficult to implement conventionally without a support base by providing a lightweight structure based on composite materials that is easy to manufacture, has excellent structural performance, and can be manufactured as a long-span structure.

[0014] Also, the present invention aims to provide a lightweight structure that can be used not only as a floor structure material but also as a ceiling and wall structure material, and can solve numerous further problems such as improving floor construction, improving the floor mortar finish for ondol (heated floor in Japan), and improving the installability of ceiling materials by utilizing structural special features.

[0015] The technical problem of the present invention is not limited to the above-described technical problems, and other technical problems not mentioned will be clearly understood by those of ordinary skill in the art from the following description.

Means for Solving the Problem

[0016] According to one aspect of the present invention for achieving the above object, it includes an upper plate made of a metal material, a lower plate made of a metal material disposed at a predetermined interval from the upper plate, and a core layer formed between the upper plate and the lower plate and made of a non-foaming polymer, and includes a bending structure in which both ends along the width direction of the overall structure are bent downward, and a multi-structural material including a unit structural material having a "C" - shaped cross-sectional structure, in which a plurality of the unit structural materials are continuously arranged in the width direction, and a lightweight structure made of a composite material can be provided.

[0017] The unit structural material may include a flat plate portion formed in the horizontal direction and a bent portion bent downward from both edge ends of the flat plate portion.

[0018] At this time, the bent portions of the adjacent unit structural materials can be structurally joined by bolting or welding.

[0019] Alternatively, the adjacent unit structural materials are arranged at a predetermined interval from each other, and finishing construction for forming a floor, ceiling, or wall can be performed in the space between the adjacent unit structural materials.

[0020] Both edge ends along the longitudinal direction of the multi-structural material are fixed to the wall of the building, and the floor structure or ceiling structure of the building can be formed.

[0021] When forming the floor structure of the building, a double floor structure can be formed by arranging the multi-structural material at an interval above a concrete slab constituting the basic framework of the building.

[0022] A vibration-reducing buffer material, a spring, or a hydraulic device can be included in the connection part between the multi-structural material and the wall body, and a buffer structure capable of absorbing vibration can be applied.

[0023] In addition, the lightweight structure made of the composite material according to one aspect of the present invention can include a superimposed structural material in which the multi-structural materials are arranged in a vertically superimposed manner.

[0024] The pair of multi-structural materials constituting the superimposed structural material can be arranged in a direction in which the bent portions face each other.

[0025] A heat insulating material and pipes for heating, ventilation, and air conditioning can be pre-installed as pre-pipes in the space between the pair of multi-structural materials and modularized.

[0026] A refractory material can be additionally installed between the heat insulating material and the multi-structural material.

[0027] Both edge ends along the longitudinal direction of the superimposed structural material can be fixed to the wall body of the building, and the floor structure or ceiling structure of the building can be formed.

[0028] Both edge ends along the longitudinal direction of the upper multi-structural material and the lower multi-structural material constituting the superimposed structural material can be fixed to the wall body.

[0029] When forming the floor structure of the building, a vibration-reducing buffer material, a spring, or a hydraulic device can be included in the connection part between the upper multi-structural material and the wall body, and a buffer structure capable of absorbing vibration can be applied.

Advantages of the Invention

[0030] According to the present invention as described above, it is possible to simply embody a strong double floor structure without the need for a separate plate reinforcement material or a supporting lower structure (beam). Therefore, there is an effect of effectively reducing interlayer noise.

[0031] In addition, when applying the lightweight structure according to the present invention in the construction field, it is possible to realize a floor structure that is ultra-lightweight and has high structural performance, minimize the structural connection between floor structures, simplify the floor mortar finishing work for ondol, and enable an ultimate dry construction method and modular construction method that are not affected by the weather. Thus, various accompanying effects can be obtained.

[0032] In addition, since the lightweight structure according to the present invention is ultra-lightweight, when applied as a structural material for buildings and ships, the total weight of the structure can be reduced, and compared with the steel plate structural materials used in conventional ships, the cost is very low, and there are also advantages in terms of cost.

[0033] The effects of the present invention are not limited to the above-described effects, and other effects not mentioned will be clearly understood by ordinary technicians from the following description.

Brief Description of the Drawings

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Mode for Carrying Out the Invention

[0035] Details regarding the object, technical configuration, and the actions and effects thereof of the present invention will be more clearly understood from the detailed description based on the drawings attached to the specification of the present invention.

[0036] The terms used in this specification are merely used to explain specific embodiments and are not intended to limit the present invention. For example, terms such as "configured" or "included" used in this specification should not be construed as necessarily including all the various components or some stages described in the invention, but may be construed as not including some of the components or some stages, or as further including additional components or stages. Also, the singular expressions used in this specification include plural expressions unless the context clearly has a different meaning.

[0037] Hereinafter, with reference to the accompanying drawings, the present invention will be described in detail by explaining the preferred embodiments of the present invention. The embodiments described below are provided so that those skilled in the art can easily understand the technical idea of the present invention, and the present invention should not be construed as being limited thereby. Naturally, the embodiments of the present invention can have various applications for ordinary technicians in this field.

[0038] The lightweight structure made of the composite material according to the present invention can include embodiments of a unit structural material as a unit, a multi-structural material composed of a combination of a number of solid unit structural materials, and a superimposed structural material formed by double superimposed arrangement of the multi-structural materials.

[0039] Figures 1 to 6 are drawings related to the description of the "unit structural material", which is the first embodiment of the lightweight structure according to the present invention. Figures 7 to 14 are drawings related to the description of the "multi-structural material", which is the second embodiment of the lightweight structure according to the present invention. Figures 15 to 18 are drawings related to the description of the "superimposed structural material", which is the third embodiment of the lightweight structure according to the present invention.

[0040] 1. First Embodiment - Unit Structural Material A. Structure of the Unit Structural Material

[0041] Referring to FIGS. 1 and 2, the unit structural material 100 according to the present invention includes an upper plate 110 and a lower plate 120 made of a metal material, and a core layer 130 formed between the upper plate 110 and the lower plate 120, and can be composed of a composite material. Here, the core layer 130 can be a layer formed of a non-foamable polymer, more preferably, a non-foamable polyurethane.

[0042] The unit structural material 100 according to the present invention includes a bending structure in which both ends along the width direction are bent downward, and can include an overall "U" - shaped cross - sectional structure, and the bent portions at both ends can serve as plate reinforcing materials.

[0043] Here, the expression that it can "include" a "U" - shaped cross - sectional structure means that the cross - sectional structure of the unit structural material 100 is not necessarily limited to a "U" shape, and any form of cross - sectional structure can be adopted as long as it includes a "U" shape.

[0044] The unit structural material 100 according to the present invention can include a flat plate portion 100F formed in the horizontal direction and bent portions 100B bent downward from both edge ends of the flat plate portion 100F. The flat plate portion 100F is a structural member that is primarily in contact with the design load when using the unit structural material 100 according to the present invention to form a floor or ceiling structural material. The bent portion 100B can enhance the structural performance by increasing the strength and rigidity of the flat plate portion 100F formed in the horizontal direction, and can function as a plate reinforcing material to prevent buckling.

[0045] As described above, as long as the unit structural material 100 according to the present invention includes a structure in which both edge ends along the width direction are bent downward as a whole, it includes the modified examples shown in FIG. 2 and can have various forms. Hereinafter, referring to FIG. 2, typical forms that the unit structural material 100 according to the present invention can take will be described.

[0046] Figure 2(a) shows the unit structural material 100 in the most basic form shown in Figure 1. Both the upper plate 110 and the lower plate 120 are provided 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.

[0047] Also, as shown in Figure 2(b), the unit structural material 100 according to the present invention can be configured such that the upper plate 110 is not bent and is formed only in the horizontal direction, and the outer surface of the core layer 130 having a "C" shaped cross-section is exposed, or as shown in Figure 2(c), the lower plate 120 is not bent and is formed only in the horizontal direction, and the inner surface of the core layer 130 having a "C" shaped cross-section is exposed.

[0048] As shown in Figure 2(b) or (c), even if one side surface of the core layer 130 is exposed, either both edge ends of either the upper plate 110 or the lower plate 120 are bent and protrude downward. Therefore, the bent portion 100B including this can exhibit sufficient structural performance as a plate reinforcing material.

[0049] When one or more of the upper plate 110 and the lower plate 120 are configured in a bent "C" shape, it is preferable to bend (bending) the metal plates constituting the upper and lower plates 110 and 120 through bending processing. This is because the bent portion 100B of the unit structural material 100 according to the present invention takes a continuous form from the flat plate portion 100F, which is structurally tough and there is no risk of thermal distortion or crack generation due to welding.

[0050] As shown in Figure 2(d), the unit structural material 100 according to the present invention may have a form in which the inner surfaces of the bent portions 100B formed at both edge ends are formed obliquely and protrude in a triangular shape. Even in this case, of course, as in the embodiments shown in Figure 2(b) or (c), either the upper plate 110 or the lower plate 120 can be formed only in the horizontal direction, and one side surface of the core layer 130 can be formed to be exposed.

[0051] In addition, as shown in Fig. 2(e), the unit structural member 100 according to the present invention can also be configured in a form in which the lower end of the bent portion 100B is bent horizontally again toward the center in the width direction of the unit structural member 100, or as shown in Fig. 2(f), the portions bent again from the lower ends of the bent portions 100B on both sides are in contact with each other and connected, so that the upper plate 110 having a "C" - shaped cross - section surrounds the lower plate 120 having a "C" - shaped cross - section.

[0052] In the embodiments shown in Figs. 2(e) and 2(f), the unit structural member 100 does not stop at the "C" - shape but has a more extended form. However, it is certain that it can include the "C" - shaped cross - sectional structure. In this structure, the portions formed vertically at both edge ends serve as plate reinforcements, and the structural performance can be realized.

[0053] Referring to Fig. 2(g), the unit structural member 100 according to the present invention further includes a separate metal angle 140, and a "C" - shaped cross - sectional structure can also be realized. 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 140 bent in an "L" - shape is inserted and coupled between the upper plate 110 and the lower plate 120 at both edge 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 140.

[0054] That is, it is not necessary that the upper plate 110, the lower plate 120, and the core layer 130 constituting the unit structural member 100 according to the present invention must all be configured in a "C" - shape. A structure in which both edge ends are bent downward by the connection of a separate member such as the metal angle 140 may also be realized.

[0055] Finally, referring to (h) of FIG. 2, the unit structural member 100 according to the present invention can also take a form in which the space between the edge ends of the upper plate 110 and the lower plate 120 is finished by a finishing member 150 made of a metal or non-metal material. The finishing member 150 finishes the edge ends of the bent portion 100B formed by the bent portions of the upper plate 110 and the lower plate 120. In the process of manufacturing the unit structural member 100 according to the present invention, the space between the upper plate 110 and the lower plate 120 can be sealed, or functions such as assisting the connection between the unit structural members 100 can be performed.

[0056] In other unit structural members 100 of the present invention, the bent portion 100B that is bent from both edge ends along the width direction and protrudes downward acts to increase the section modulus of the entire structure, and the section modulus can be influenced by the height and shape of the bent portion 100B which is a reinforcing structure.

[0057] In order for the bent portion 100B to effectively embody the structural performance as a plate reinforcing material, it is preferable to include a metal material with 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 140 is used to form the lower bent portion 100B.

[0058] FIG. 19 shows a steel plate structural member 10 composed only of metal, which is often used as a structural member of a general ship. In the conventional steel plate structural member 10 shown in FIG. 19, a plate reinforcing member 20 is welded to the lower surface for structural reinforcement. However, such a conventional method has a problem that welding distortion occurs when connecting the plate reinforcing member 20 to the lower surface of the steel plate structural member 10.

[0059] However, unlike the conventional iron plate structural member 10 in which the plate and the reinforcing member that function as structural members are separately manufactured and then joined by welding or bolting, the unit structural member 100 according to the present invention has a form in which the flat plate portion 100F and the bent portion 100B are integrally manufactured and the plate reinforcing structure is already included in the plate reinforcing structure itself. Therefore, there is no possibility of occurrence of welding distortion problems as in the prior art, and there is no need for additional hole construction or local structural reinforcement work for bolted connection between the plate and the reinforcing member, and it can have structurally stable performance.

[0060] Another problem with the prior art is that when constructing a composite structure of an upper plate and a lower plate with thin metal plates, it may be impossible to perform post-welding of plate reinforcing materials to the thin metal plates themselves. In order for the plate reinforcing material to function properly structurally, a welding joint strength of a certain level or more is required. Usually, a weld leg length of 70% or more of the thickness of the web structure of the plate reinforcing material is required as a minimum. That is to say, in order to perform post-welding of a metal plate reinforcing material with a web thickness of 6 mm, a weld leg length of at least 4 mm or more is required.

[0061] In addition, when the thickness of the base iron plate is much thinner than the weld leg length, there is a problem that not only welding distortion but also overall structural stability is damaged. In order to achieve a weld leg length of a certain thickness or more, when using a general welding equipment such as CO2 welding, a phenomenon of carbonization of the internal core due to welding heat is likely to occur. In this case, a loss of adhesion strength also occurs, so that the structural stability is greatly reduced.

[0062] However, since the unit structural member 100 according to the present invention itself has a form in which the bent portion 100B is already included, it is possible to manufacture an optimized composite structure with a structure in which the thicknesses of the upper plate 110 and the lower plate 120 are much thinner than the thickness required for welding.

[0063] In addition, the unit structural material 100 according to the present invention is characterized in that not only the flat plate portion 100F but also the bent portion 100B having the function of a plate reinforcing material is composed of a composite material that is not a single metal material. According to such a structure, there is an advantage that the weight of the structure can be reduced by about 40 to 50% compared to the case of using a plate reinforcing material made of only metal.

[0064] 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 formed to be 0.4 to 20 mm, respectively. At this time, as will be described later, when the unit structural materials 100 according to the present invention are joined to each other as individual modules to form the multi-structural material 200, or when the unit structural material 100 is to be connected to another structure, welding work may have to be performed. 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 formed to be 0.4 mm or more for easy laser welding. Further, in order to achieve the weight reduction 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 presents 0.4 to 10 mm as the most preferable thickness of the metal plates constituting the upper plate 110 and the lower plate 120.

[0065] The thickness of the core layer 130 of the unit structural material 100 according to the present invention can be variously configured from 3 to 40 mm. At this time, when the core layer 130 is configured to have a "C" - shaped cross - sectional shape and includes all the portions formed in the horizontal direction and the vertical direction, the thicknesses of the core layer 130 formed in both directions may be different. That is, the thickness of the core layer 130 of the flat plate portion 100F and the thickness of the core layer 130 of the bent portion 100B can be the same, but can also be adjusted differently. When trying to form different thicknesses, it is preferable that the thickness of the core layer 130 of the bent portion 100B, which functions as a plate reinforcing material, is formed thinner than the thickness of the core layer 130 of the flat plate portion 100F.

[0066] The overall 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 portion 100B protruding downward can be formed to be 40 to 500 mm as a level capable of embodying the structural performance capable of complementing the overall deflection amount of the structural material. Here, the height of the bent portion 100B can mean the height from the lowermost end of the unit structural material 100 to the lower surface of the upper plate 110.

[0067] Within the ranges presented above, when designing the thickness, width, height, etc. of each component, the unit structural material 100 according to the present invention can be manufactured to a level where the maximum span (length) reaches as much as 6 to 10 m. That is, the unit structural material 100 according to the present invention can be manufactured as a long-span structure of about 6 to 10 m. The reason for this is that the core layer 130, which is composed of a non-foaming polymer with a specific gravity in the range of 0.8 to 1.8 and is very lightweight compared to metals, is firmly joined between the upper plate 110 and the lower plate 120, has basic structural performance, and the bent portion 100B protruding downward from both edge ends of the unit structural material 100 functions as a plate reinforcing material.

[0068] The unit structural material 100 according to the present invention, which is manufactured as a long-span structure of 6 to 10 m, can exhibit structural performance equivalent to that of reinforced concrete in the direction across the width of the structural material within the range of that length without adding a separate reinforcing material. Therefore, as will be described later, when using the multi-structural material 200 or the superimposed structural material 300, which is composed of a combination of a number of the unit structural materials 100, as a floor structural material, it is possible to realize a perfect double-floor structure without a separate lower support base.

[0069] As a preferred embodiment, when the thicknesses of the upper plate 110 and the lower plate 120 of the unit structural material 100 according to the present invention are each formed to be 1 mm and the core layer 130 is formed of a 5-mm thin core, the overall thickness of the unit structural material 100 is only 7 mm. However, in this structure, when the width of the unit structural material 100 is formed to be 700 mm, the height of the bent portion 100B is formed to be 100 mm, and both ends are fixedly installed at a span (length) of 7 m, it can be confirmed through structural calculations that when a distributed load of 1 kN per square metre is applied on the unit structural material 100, the maximum deflection amount is 14 mm or less, and it is possible to ensure very strong structural performance.

[0070] As described above, in addition to the material characteristics in which the unit structural material 100 according to the present invention is composed of a composite material of the upper and lower plates 110 and 120 made of a metal material and the core layer 130 made of a non-foamed polymer, it is possible to embody an ultra-lightweight and significantly excellent structural performance by the plate reinforcement structure of the bent portion 100B included in the unit structural material 100 itself.

[0071] Specifically, the unit structural material 100 manufactured from the composite material according to the present invention can embody equivalent structural performance with a weight that is approximately 50 to 60% less than that of the steel plate structural material mainly used in the ship field, and can embody equivalent structural performance with a weight that is approximately 15 to 25% less than that of the reinforced concrete structure mainly used in the building field.

[0072] Also, it goes without saying that the multi-structural material 200 and the laminated structural material 300, which are configured by connecting and laminating a large number of the high-performance unit structural materials 100 as described above, can naturally have even stronger structural characteristics.

[0073] More preferably, the unit structural member 100 according to the present invention can be manufactured so as to satisfy the criterion of a deflection amount of at least L / 480. Here, "L" means the length (span) of the unit structural member 100. If the central portion of the unit structural member 100 deflects by 1 / 480 or more of the total length of the unit structural member 100, it cannot be regarded as satisfying the criterion. As described above, the unit structural member 100 according to the present invention is manufactured with a length (span) of 7 m, and the deflection amount generated when both ends are fixed is 14 mm or less. This is a numerical value of 7,000 / 480 ≒ 14.583 (mm) or less, and it can be known that the criterion of the L / 480 deflection amount is satisfied.

[0074] The structural performance of the unit structural member 100 for satisfying the criterion of the deflection amount as described above can be realized by adjusting the height and shape of the bent portion 100B and the like. In addition, by imparting an adhesive strength of a certain level or more between the upper plate 110, the lower plate 120, and the core layer 130, it is possible to assist in realizing the structural performance of the unit structural member 100. Specifically, the non-foaming polymer constituting the core layer 130 has an adhesive force by itself. As will be described later, in the process of curing the stock solution of the liquid non-foaming polymer, the surfaces in contact with the upper plate 110 and the lower plate 120 are hermetically adhered. However, in the present invention, an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, can be imparted between the upper plate 110 and the core layer 130 and between the lower plate 120 and the core layer 130.

[0075] As in the embodiment shown in FIG. 2(g), even in a form in which the bent portion 100B is constituted by a separate metal angle 140, the metal angle 140 can have sufficient strength by being inserted and adhered between the upper plate 110 and the lower plate 120 without the need for welding.

[0076] The metal angle 140 can be inserted between the upper plate 110 and the lower plate 120, and the surfaces in contact can be adhered by an adhesive. The surface in contact with the core layer 130 can also be adhered by the adhesive force of the non-foaming polymer itself that forms the core layer 130. At this time, in order to prevent the peeling phenomenon of the adhesive surface, an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, can be imparted between the upper plate 110 and the lower plate 120 and the metal angle 140 in the same manner as described above.

[0077] In addition, when constructing the core layer 130 of the unit structural material 100 according to the present invention, it is also possible to additionally use a high-performance heat insulating material in which heat insulation and structural performance are already embodied. In this case, a high-performance heat insulating material with a low thermal conductivity is additionally arranged between the upper plate 110 and the lower plate 120, so that excellent performance can be achieved in terms of heat insulation.

[0078] More specifically, the core layer 130 can be formed by arranging a high-performance heat insulating material having a thermal conductivity lower than 0.02 W / Mk together with a non-foaming polymer between the upper plate 110 and the lower plate 120. As an example, it further includes a vacuum insulating panel (VIP: Vacuum Insulation Panel) having a thermal conductivity of 0.004 W / mK level. When forming the core layer 130, it is assumed that the total thickness of the unit structural material 100 increases to 20 - 40 mm. However, in terms of heat insulation, it is possible to achieve heat insulation performance that is about 6 - 10 times better than that of a general EPS (Expanded Polystyrene) heat insulating material. Moreover, due to the characteristics of the composite material, the structural strength increases in proportion to the square or cube of the increase in thickness, so excellent structural performance can be achieved while being lightweight.

[0079] Also, when the vacuum insulating material is contained in the non-foaming polymer, the vacuum insulating material can be more effectively protected from external impacts. The gas entry and exit to the vacuum insulating material are perfectly blocked by the closed structure of the non-foaming polymer, and the effect of extending the life of the vacuum insulating material almost semi-permanently can be achieved.

[0080] When the core layer 130 is composed only of a non-foamed polymer, there is an advantage that the thickness of the unit structural material 100 can be optimized to be very thin. When additionally including a high-performance heat insulating material such as a vacuum heat insulating material together with the non-foamed polymer, in terms of manufacturing the unit structural material 100, there is an advantage that it is more convenient (since the non-foamed polymer stock solution can be applied to the surface of the high-performance heat insulating material and used like an adhesive) and excellent heat insulating performance can be obtained. Therefore, considering the advantages of each method, when forming the core layer 130 of the unit structural material 100 according to the present invention, it can be said that it is possible to select and apply whether to use the non-foamed polymer alone or to use the high-performance heat insulating material in parallel.

[0081] For reference, when the core layer 130 is composed only of a high-performance heat insulating material, the bonding force with the upper plate 110 and the lower plate 120 is weak, so it is difficult to ensure sufficient structural performance. Only when the non-foamed polymer surrounding the high-performance heat insulating material maintains a form firmly fixed by adhesion between the upper plate 110 and the lower plate 120, can the unit structural material 100 of the present invention obtain satisfactory structural performance.

[0082] I. Manufacturing method of unit structural material

[0083] Next, referring to FIGS. 3 to 6, a specific manufacturing method of the unit structural material 100 according to the present invention will be described.

[0084] The thickness of the plate reinforcing material used in a ship varies from 6 to 30 mm, but usually a thin one with a thickness of about 6 to 15 mm is used. When replacing this with the structure of the non-foamed polymer and metal composite material proposed in the present invention, the upper plate 110 and the lower plate 120 can be made of metal thin plates having a thickness at the level of 1 to 3 mm, and the thickness of the non-foamed polymer constituting the core layer 130 can be formed in a very thin structure of about 5 to 15 mm.

[0085] However, it is not practically easy to form a thin non-foamed polymer structure as described above. This is because non-foamed polymers are basically viscous, so if the space to be filled is formed too narrow, when injecting the stock solution, a large frictional resistance will occur and it is difficult to spread evenly within the space. Considering such manufacturing characteristics between metal and non-foamed polymers, a certain classification rule that specifies the basic performance and structural requirements of ships recommends that the core composed of non-foamed polymers be formed with a thickness of 15 mm or more. If not following this, separate approval needs to be obtained.

[0086] The manufacturing method described below relates to the case where the core layer 130 of the unit structural material 100 is formed of a non-foamed polymer (for example, non-foamed polyurethane). In particular, it is proposed to solve the above-mentioned difficulty in manufacturing, that is, the problem that it is difficult to form the core layer 130 composed of non-foamed polymers thinly. More preferably, even when the core layer 130 is formed with a thickness of 15 mm or less, it presents a method that enables the non-foamed polymer to be evenly filled in the space and obtain a uniform core layer 130.

[0087] 1) First manufacturing method

[0088] The progress of the first manufacturing method of the unit structural material 100 according to the present invention will be described with reference to FIG. 3.

[0089] First, with the upper plate 110 inverted, pour the liquid non-foamed polymer stock solution (S) into the space formed by the flat part and the frame part of the upper plate 110. At this time, the amount of the non-foamed polymer stock solution (S) can be poured in an amount about 2% more than the amount that can completely fill the space formed between the upper plate 110 and the lower plate 120 when the lower plate 120 is later covered (that is, the amount corresponding to the actual volume occupied by the core layer).

[0090] Then, with the non-foaming polymer stock solution (S) poured into the space of the upper plate 110, the lower plate 120 is inserted from above and pressed downward. The lower plate 120 can be pressurized using a hydraulic device or the like until a predetermined fixed interval is achieved between it and the upper plate 110. At this time, in order to maintain the designed thin thickness of the interval between the upper plate 110 and the lower plate 120, a separate spacer can be additionally arranged between the upper plate 110 and the lower plate 120.

[0091] The non-foaming polymer stock solution (S) buried in the lower part of the space of the upper plate 110 can melt into the vertical spaces at both edges, that is, the space between the upper plate 110 and the lower plate 120 formed in the vertical direction, by the pressing force of the lower plate 120. At this time, since the non-foaming polymer stock solution (S) is actually filled in an amount more than the volume occupied by the core layer 130, the excess amount may be extruded outward and discharged.

[0092] The non-foaming polymer stock solution (S) evenly filled between the upper plate 110 and the lower plate 120, including being filled up to the vertical space, hardens over time to form the core layer 130, and the production of the unit structural material 100 according to the present invention is completed by the formation of the core layer 130.

[0093] The first manufacturing method as described above is not a method of injecting the non-foaming polymer stock solution (S) into a sealed space, but a method of pouring and filling it into a released space. By overcoming the frictional resistance generated during the injection of the non-foaming polymer stock solution (S) through pressurization, a thin plate reinforcement structure can be formed. Furthermore, there is an advantage that the operation can be carried out while visually checking whether the non-foaming polymer stock solution (S) is normally filled in the entire structure corresponding to the core layer 130.

[0094] In the above-described first manufacturing method, as the operation proceeds in the open cavity method, an area where the non-foaming polymer stock solution (S) comes into contact with air is generated, and bubbles can be formed. However, as described above, such bubbles can be removed through a process of injecting a non-foaming polymer stock solution (S) in an amount at least 2% more than the amount corresponding to the actual volume of the core layer 130 and extruding the excess to the outside of the structural material.

[0095] For reference, FIG. 3 illustrates, as an example, the most basic form of the unit structural material 100 according to the present invention (the form shown in FIGS. 1 and 2(a)). If there is a part of the upper plate 110 or the lower plate 120 that is not bent and is formed only in the horizontal direction, the shape of the plate can be temporarily made into a "U" shape using seaming, and after the non-foaming polymer stock solution (S) hardens and the core layer 130 is completed, the seaming can be removed, and this manufacturing method can be applied.

[0096] 2) Second manufacturing method

[0097] Referring to FIG. 4, the second manufacturing method of the unit structural material 100 according to the present invention uses 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 the sealed space. However, not only one injection tube for injecting the non-foaming polymer stock solution but also a configuration in which it is divided into several small tubes.

[0098] Normally, when two types of liquids of organic compounds such as ISO and polyol are mixed in a non-foaming polymer, a chemical reaction occurs at the same time, and curing starts from this time. At this time, since the time for the chemical reaction to occur is only a few minutes, the injection of the non-foaming polymer stock solution must also be completed within a few minutes. In addition, since the non-foaming polymer stock solution has viscosity by itself, it may be difficult to spread evenly within a few minutes.

[0099] This manufacturing method is for solving the difficulties in the process as described above. By dividing the injection pipe for injecting the non-foaming polymer stock solution into several small pipes and arranging them densely 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.

[0100] In this manufacturing method as well, among the upper plate 110 and the lower plate 120, if there is one that does not have a "U" shape, it is possible to temporarily make the shape of the plate into a "U" shape using seaming and proceed with the work, which is the same as the first manufacturing method described above, and it goes without saying that it is also applied in the same way in the manufacturing methods described later.

[0101] Also, as shown in Fig. 2(h), when the unit structural material 100 according to the present invention includes the finishing member 150, the finishing member 150 should be able to substitute for the role of seaming.

[0102] 3) Third manufacturing method

[0103] Referring to Fig. 5, in the third manufacturing method of the unit structural material 100 according to the present invention, a method is used in which a sealed space is formed between the upper plate 110 and the lower plate 120, and the non-foaming polymer stock solution is injected into the sealed space, but the injection is carried out while evacuating the air in the sealed space using a vacuum pump (VP).

[0104] More specifically, after forming a sealed space between the upper plate 110 and the lower plate 120, on the one hand, an injection pipe is inserted to inject the non-foaming polymer stock solution, and on the opposite side, the air in the sealed space is inhaled using a vacuum pump (VP).

[0105] According to such a third manufacturing method, when injecting the non-foaming polymer stock solution due to the pressure difference between the inside and outside of the sealed space, not only is it possible to inject thinly while overcoming the frictional resistance, but also there is an advantage that rapid injection is possible due to the suction force of the vacuum pump (VP).

[0106] 4) Fourth manufacturing method

[0107] For the upper plate 110 and the lower plate 120 used in manufacturing the unit structural material 100 according to the present invention, metal plates much thinner than the iron plates generally used for ships are used. Therefore, although there are some construction-related nuisances due to this, it is precisely because the thickness of the metal plate is too thin that it is difficult to maintain the shape of the plate and manage flatness before or during the process of filling the core (non-foamable polymer).

[0108] Conventionally, in the process of filling the core between two plates, spacers have been used to maintain the shape (or the interval). Also, when using a non-foamable polymer as the core, since it has the property of swelling slightly during the hardening process, the upper plate is sometimes pressed with a considerable load. However, when the thickness of the metal plates forming the upper plate 110 and the lower plate 120 is formed to be very thin below a certain level as in the present invention, it is difficult to maintain the shape of the plate and maintain flatness by the conventional methods described above.

[0109] In addition, a phenomenon in which the plate sags due to the weight of the upper plate also occurs. At this time, when the thickness of the core is formed thick enough, since the strength of the chemical reaction is also strong, it is possible to push up the sagging upper plate again by utilizing the swelling force. However, when the core layer 130 is formed thin as in the present invention, since the swelling force is weak, it is not possible to restore the sag of the upper plate 110 due to its own weight.

[0110] Moreover, the unit structural material 100 according to the present invention includes a structure that is bent downward. In this case, due to the characteristic that the upper plate 110 and the lower plate 120 are composed of thin plates, it is also very difficult to maintain a constant bending angle.

[0111] The fourth manufacturing method of the unit structural material 100 according to the present invention was proposed to solve the difficulties in the manufacturing method as described above. If the above-described first to third manufacturing methods are manufacturing methods related to the filling of non-foamed polymers, the fourth manufacturing method can be regarded as a manufacturing method related to maintaining the shape and flatness of the entire structural material before and during the injection of the non-foamed polymer.

[0112] Specifically, as shown in FIG. 6, when a magnet (M) is placed on the upper surface of the lower plate 120 disposed on the upper part in a state where the space between the upper plate 110 and the lower plate 120 is filled with the non-foamed polymer stock solution (S), the upper surface of the lower plate 120 comes into close contact with the magnet (M) due to the magnetic field generated by the magnet (M), and a flat state can be maintained.

[0113] For reference, in this embodiment, since the manufacturing process of the unit structural material 100 proceeds with the upper plate 110 and the lower plate 120 inverted, the magnet (M) is placed on the upper surface of the lower plate 120. If the upper plate 110 is placed upward and the manufacturing process proceeds, the magnet (M) should be placed on the upper surface of the upper plate 110. That is, the plate placed on the floor does not need to consider the flatness problem, and based on the non-foamed polymer stock solution (S), it should be placed on the upper side and the magnet (M) should be placed on the upper surface of the plate.

[0114] Here, the magnet (M) includes an electromagnet and can be understood as a concept including all magnetic bodies that can generate a force to attract metals. The magnet (M) does not need to be configured to have a size corresponding to the entire area of the plate whose flatness is to be maintained. Even if it occupies only a partial area, the effect of making the entire plate flat can be obtained. Also, a plurality of magnets (M) can be placed on the plate. When only one magnet (M) is used, it is desirable to place it at the center of the plate.

[0115] In addition, not only can the upper plate 110 and the lower plate 120 be placed horizontally, but magnets (M) can also be placed on the side surfaces of the upper plate 110 and the lower plate 120 erected vertically on the same principle to maintain flatness and obtain a desired bending angle.

[0116] In the drawings, for the sake of convenience, only the arrangement positions of the magnets (M) are simply shown. However, the magnets (M) can be configured to be included in a work jig or a surface plate for fixing the positions of the upper plate 110 and the lower plate 120. In this case, even if no separate gripping portion is provided on the work jig, the upper plate 110 and the lower plate 120 provided with a metal plate can also enjoy the accompanying effect of being easily gripped by the attracting force of the magnets.

[0117] When applying this manufacturing method, if there is no portion standing upright in the vertical direction among the upper plate 110 and the lower plate 120 (that is, when it is not in the shape of "C"), it is not necessary to arrange the magnet (M) in this portion.

[0118] Also, this manufacturing method can also be implemented by using a vacuum suction device instead of the magnet (M). Specifically, by sucking a specific portion of the plate whose flatness is to be maintained with a vacuum suction device and applying a tensile force, the form of the structural material can be maintained and the flatness can be maintained.

[0119] Similar to the case of applying the magnet (M), the vacuum suction device can also execute the flatness maintaining function by providing an attracting force only for a partial area that is not the entire area of the plate. Preferably, it is better to suck the central portion of the plate whose flatness is to be maintained. Also, it is possible to apply a plurality of vacuum suction devices on one plate.

[0120] The unit structural 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 thickness throughout, so that uniform structural performance can be realized. Also, by solving the flatness problem in the manufacturing process, the amount of the spacer disposed between the upper plate 110 and the lower plate 120 can be greatly reduced, and there is also an effect of being able to reduce the manufacturing man-hours and costs.

[0121] In addition, the above-described first to fourth manufacturing methods can also be applied in parallel with two or more methods. For example, while executing the first manufacturing method in a sealed space that is not an open cavity, it is possible to evacuate the air in the sealed space using the vacuum pump of the third manufacturing method. Also, similar to the second manufacturing method, it is possible to apply the vacuum pump of the third manufacturing method while injecting the non-foaming polymer stock solution using several injection tubes. Further, in the case of the fourth manufacturing method, since it is a method applied to maintain the form and flatness of the structural material, it can be applied in parallel with any other manufacturing method.

[0122] 2. Second Embodiment - Multi-Structural Material

[0123] A. Structure of the Multi-Structural Material

[0124] The multi-structural material 200 having another embodiment of the lightweight structure according to the present invention can be configured by connecting a large number of the above-described unit structural materials 100. In order to actually form the structures of the floor, ceiling, and wall of a building or a ship, it is necessary to apply the multi-structural material 200 with a sufficient area secured by a continuous arrangement of a large number of unit structural materials 100.

[0125] Referring to FIGS. 7 and 8, the multi-structural material 200 according to the present invention can basically be fabricated by structurally coupling a large number of unit structural materials 100 along the width direction. At this time, the adjacent unit structural materials 100 can be connected by restraining the opposing bent portions 100B by welding or bolt fastening.

[0126] More specifically, as shown in FIG. 7, when the outer surfaces of the opposing bent portions 100B are formed of metal, either welding or bolt fastening can be freely applied. As shown in FIG. 8, when the outer surface of the core layer 130 constituting the bent portion 100B is exposed, bolt fastening can be more preferably applied.

[0127] The multi-structural material 200 composed of the joining of a plurality of unit structural materials 100 can be located anywhere above or below a conventional concrete slab. That is, the multi-structural material 200 according to the present invention can be applied anywhere in the floor or ceiling structure of a building, and can of course also be applied to the wall structure of a building as needed.

[0128] Note that the unit structural materials 100 according to the present invention can also be structurally connected to the wall only at both ends along the longitudinal direction without directly joining the individual modules to form a floor or ceiling structure. Specifically, a large number of unit structural materials 100 are fixed to the wall only at both ends along the longitudinal direction in the space where the floor or ceiling structure is to be formed, and the unit structural materials 100 adjacent to each other along the width direction can be arranged in close contact with each other, or can be arranged at a predetermined interval. Then, a floor finishing material can be constructed on the upper part of a large number of continuously arranged unit structural materials 100, or a ceiling finishing material can be constructed on the lower part to form a floor structure or a ceiling structure.

[0129] That is, the multi-structural material 200 according to the present invention does not necessarily require the joining between the unit structural materials 100. Whether the unit structural materials 100 constituting the multi-structural material 200 are in close contact with each other or are separated at a predetermined interval, by performing finishing work on the space therebetween, it is possible to form a floor or ceiling structure without structural problems.

[0130] Also, as described above, in a structure where the unit structural materials 100 are not joined to each other in the width direction, when a floor impact occurs, only the individual unit structural materials 100 that receive the impact vibrate without the entire floor vibrating, so there is an advantage that the impact wave is locally limited. Also, when an individual unit structural material 100 vibrates, friction with other adjacent unit structural materials 100 does not occur or can be minimized, so it is possible to expect performance of reducing vibration / noise.

[0131] I. Application examples and effects of the multi-structural material

[0132] Next, specific application examples of the multi-structural material 200 according to the present invention and the resulting effects will be described.

[0133] 1) Floor structure of a building (double floor structure)

[0134] The multi-structural material 200 according to the present invention can typically be applied to the double-floor structure of a building. Hereinafter, the implementation of the double-floor structure using the multi-structural material 200 according to the present invention will be described in detail.

[0135] Referring to FIG. 9, both edge ends of the multi-structural material 200 according to the present invention can be fixed to the wall of the upper floor building along the longitudinal direction. At this time, the multi-structural material 200 is arranged at a slight interval from the concrete slab constituting the upper floor, and it is only when implemented in a double-floor structure that the performance of interlayer noise reduction can be significantly increased.

[0136] Generally, multi-story buildings such as apartments, houses, officetels, and buildings are divided between the upper and lower floors by a concrete slab. The concrete slab is used as a floor on the upper floor and as a ceiling on the lower floor.

[0137] Conventionally, floor construction has been carried out on the concrete slab so that it can be used as a floor on the upper floor. Specifically, a heat insulating material and hot water pipes are installed on the concrete slab, and finally mortar work is performed thereon to form a floor on which people can actually walk.

[0138] However, the conventional floor structure as described above has a problem that interlayer noise is serious because the impact and friction applied to the floor are transmitted to the lower floor through the concrete slab. Although attempts have been made to solve the problem of interlayer noise by implementing a double-floor structure, as described above, the conventional double-floor structure still has a problem that interlayer noise is transmitted through the support base that supports the upper floor on the concrete slab.

[0139] However, when forming the upper floor with the multi-structural material 200 according to the present invention to embody a double floor structure, even if each unit structural material 100 constituting the multi-structural material 200 is configured as a long-span structure, since the amount of deflection is very limited, sufficient structural performance can be ensured only by fixing both edge ends along the longitudinal direction of the multi-structural material 200 to the wall body of the building. Therefore, there is no need to separately install a support base between the multi-structural material 200 and the concrete slab, and the upper floor and the concrete slab can be structurally separated, enabling the embodiment of a double floor structure that is very effective in reducing interlayer noise.

[0140] Referring to FIG. 9, the effect of reducing interlayer noise by applying the multi-structural material 200 according to the present invention will be described more specifically.

[0141] Generally, interlayer noise is classified into two types: primarily, the weight or frictional impact noise generated on the upper floor is transmitted through the floor structure, and secondarily, it is transmitted from the upper floor through the wall body. However, when a double floor structure is embodied using the multi-structural material 200 according to the present invention, the impact noise generated on the multi-structural material 200 side that constitutes the upper floor on the upper floor is converted into sound and transmitted to the lower concrete slab. That is, since the impact noise is transmitted in a manner of sound energy rather than directly by vibration, the total amount of energy transmitted to the lower floor can be significantly reduced.

[0142] In addition, the vibration transmitted from the multi-structural material 200 that constitutes the upper floor on the upper floor through the wall body is not directly transmitted to the ceiling finishing material on the lower floor but is first transmitted to the concrete slab. Therefore, the amount of vibration and sound energy applied to the ceiling finishing material on the lower floor can be greatly reduced.

[0143] In addition, when connecting the multi-structural material 200 to the building wall, the present invention proposes various buffer connection structures between the multi-structural material 200 and the wall so as to more effectively block noise transmission through the wall, and through this, attempts to maximize the above-described effect of reducing interlayer noise. Hereinafter, with reference to FIGS. 10 to 13, connection structures applicable between the multi-structural material 200 according to the present invention and the wall will be examined respectively.

[0144] First, with reference to FIG. 10, the connection structure of the first wall will be examined. In the connection structure of the first wall, an anchor pad 211 is provided on the building wall, and metal plates 212 for fastening to the anchor pad 211 are fixed by welding at both ends along the longitudinal direction of the multi-structural material 200. The anchor pad 211 and the metal plate 212 are fixed and connected to each other through bolt fastening. At this time, a vibration-reducing buffer material can be arranged between the anchor pad 211 and the metal plate 212 so as to relieve the impact transmitted from the multi-structural material 200 to the wall.

[0145] In addition, when fixing the multi-structural material 200 according to the present invention to the wall, it is not necessary to fix all of the numerous unit structural materials 100 constituting the multi-structural material 200 to the wall. As long as a sufficient structural performance against the design load can be ensured, it is also possible to fix only a part of the numerous unit structural materials 100 to the wall.

[0146] Next, with reference to FIG. 11, the connection structure of the second wall will be examined. In the connection structure of the second wall, the lower part of the anchor pad 221 installed on the building wall is provided in an L-shaped angle (or an L-shaped angle member is coupled to the lower end of the anchor pad 221), and the lower end portion of the metal plate 222 is inserted into the space formed by the lower L-shaped angle of the anchor pad 221 and can be supported while preventing horizontal detachment. The upper end portion of the metal plate 222 can be fixed to the anchor pad 221 or the wall through bolt fastening.

[0147] Then, for the purpose of mitigating the impact transmitted from the multi-structural material 200 to the wall, vibration reduction buffer materials or springs can be additionally arranged between the metal plate 222 and the anchor pad 221.

[0148] In this connection structure, the lower end of the metal plate 222 is simply inserted into the space and accommodated and supported without being mechanically fastened by a separate member, and only the upper end is fastened by bolt tightening. That is, the metal plate 222 is placed on the anchor pad 221 including the L-shaped angle, and only the upper end needs to be fixed to the wall side. Therefore, the workability at the site is very simple and a structurally strong connection is possible.

[0149] Next, referring to FIG. 12, the connection structure of the third wall will be described. In the connection structure of the third wall, the anchor pad 231 installed on the wall of the building and the metal plate 232 welded and fixed to the edge along the longitudinal direction of the multi-structural material 200 are connected by a hinge method. The metal plate 232 is configured to be rotatable about the hinge axis, and an elastic spring 233 is arranged between the anchor pad 231 and the metal plate 232, so that the impact transmitted from the multi-structural material 200 to the wall can be mitigated.

[0150] In this connection structure, it is also possible to arrange a vibration reduction buffer material between the anchor pad 231 and the metal plate 232 instead of the spring 233, or to arrange a vibration reduction buffer material together with the spring 233.

[0151] If the connection structure of the second wall shown in FIG. 11 allows some movement within a predetermined range without restricting the lower end of the metal plate 222, the connection structure of the third wall shown in FIG. 12 can be understood as a structure that restricts the lower end of the metal plate 232 but allows the entire plate to behave flexibly with respect to vibration through the hinge connection.

[0152] Finally, the connection structure of the fourth wall shown in FIG. 13 is a method of connecting the multi-structural material 200 through the vibration reduction device 241 without directly connecting it to the building wall. Here, the vibration reduction device 241 may be a hydraulic device or a spring device that can absorb vibrations in the vertical direction.

[0153] When applying the fourth wall connection structure, the vibration caused by the impact generated in the multi-structural material 200 is not transmitted to the wall. Also, the vibration transmitted from the multi-structural material 200 to the concrete slab can be absorbed by the vibration reduction device 241, so the impact transmitted in the vertical direction can also be effectively alleviated.

[0154] Also, although not shown in the drawings, in addition to the above-described first to fourth wall connection structures, various buffer materials are arranged in the space between the multi-structural material 200 and the concrete slab to embody an additional damping effect, thereby further reducing interlayer noise is also possible.

[0155] When the multi-structural material 200 according to the present invention is used as the floor structure of a building, the following effects are obtained.

[0156] (1) First, there is an effect of reducing interlayer noise through the implementation of a double floor structure.

[0157] As described above, when applying the multi-structural material 200 according to the present invention, a strong double floor structure without the need for a support base can be implemented, thus significantly reducing interlayer noise.

[0158] (2) Second, there is an effect of simplifying the ondol floor mortar finishing work.

[0159] As described above, since the multi-structural material 200 according to the present invention has far superior structural performance, there is no need to perform ondol construction (heating construction) on a lightweight floor to enhance structural strength as in the conventional double-floor structure. Therefore, when installing the multi-structural material 200 according to the present invention on a conventional concrete slab, the work of hot water pipes and pipes for heating and cooling required for ondol construction can be conveniently carried out on the conventional concrete, and there is an advantage that there is no need to perform a separate floor mortar finishing mortar work.

[0160] In the conventional floor mortar finishing work for ondol, after installing the heat insulating material on the concrete slab and arranging the hot water pipes, in order to form a flat floor on which people can walk, it was necessary to perform floor mortar work or install a separate dry ondol panel to start the finishing floor material construction. However, since the multi-structural material 200 according to the present invention functions as a sufficient structural material by itself, the conventional separate floor mortar work or dry ondol panel installation work is not required, and the finishing floor material construction can be immediately carried out on the multi-structural material 200, so that the floor mortar finishing work for ondol can be greatly simplified.

[0161] Also, since the structure for raising the temperature is much simpler and more streamlined, it is also much more advantageous in terms of thermal efficiency.

[0162] (3) Thirdly, there is an effect of simplifying the step construction.

[0163] The production of the step structure for the floor slab of the toilet and the entrance is also very convenient. Usually, the toilet and entrance floors are designed to have a step about several tens of mm lower than other floor slabs. In the conventional construction method, separate formwork work and floor mortar finishing work were required to form such a step. However, according to the present invention, if all the floor slabs on the same floor are made flat and the step construction is only carried out on the multi-structural material 200, the step construction can be simplified.

[0164] 2) Ceiling structure of a building

[0165] Referring to FIG. 14, it is also possible to install the multi-structural material 200 according to the present invention under a concrete slab and utilize it as a ceiling structure.

[0166] In this case, since the ceiling finishing material of the lower floor can be directly attached to the lower surface of the multi-structural material 200, separate support base construction and carpentry work for attaching the ceiling finishing material are not required, and the ceiling work is simplified.

[0167] In addition, since various pipes and concealed pipes (for example, ceiling-embedded air conditioners) to be installed on the ceiling can be easily attached to the multi-structural material 200 according to the present invention, the application of the modular construction method is also possible through pre-piping.

[0168] When the multi-structural material 200 according to the present invention is used as a ceiling structure, it may be connected to the wall of the building through simple mechanical fastening such as bolt fastening without considering the function for inter-story noise. However, the present invention is not limited thereto, and it goes without saying that a buffer structure such as the first to fourth wall connection structures described above may be applied as necessary.

[0169] 3) Ship structure

[0170] The multi-structural material 200 according to the present invention is applicable not only to buildings but also to the deck of a ship and the floor structure of a ship deckhouse, and when applied to a ship, it can have the following effects.

[0171] (1) First, it has the effect of solving the problem of conventional welding thermal distortion.

[0172] As described above, conventionally, in order to form the deck of a ship, the steel plate structural material 10 as shown in FIG. 19 has been used. In this case, by welding the plate reinforcing material 20 under the steel plate structural material 10, the problem of serious thermal distortion could not be avoided.

[0173] Also, usually, when only considering the structural performance as a ship deck, the thickness of the steel plate structural member 10 may be formed to be approximately 6 mm. However, considering the thermal distortion due to the welding of the plate reinforcing member 20, there are frequently cases where the thickness of the steel plate structural member 10 is first increased to about 10 mm for manufacturing. However, even if the thickness of the steel plate structural member 10 is increased, the problem of thermal distortion due to the welding of the plate reinforcing member 20 still exists. Therefore, in most cases, a significant amount of man-hours are invested in repair work by thermal processing after the welding of the plate reinforcing member 20.

[0174] However, in the lightweight structure according to the present invention, since the bent portion 100B that functions as a plate reinforcing member is already included in the structure of the unit structural member 100, when applying this, welding for attaching the plate reinforcing member becomes unnecessary, and the welding amount required for all processes and the accompanying thermal distortion can be significantly reduced. Therefore, the problem of thermal distortion due to the welding of the steel plate structural member 10 that is still mainly used in the shipbuilding industry field at present can be fundamentally solved.

[0175] Also, when manufacturing the multi-structural member 200 according to the present invention through the welding between the unit structural members 100, since the welding between the unit structural members 100 that already have rigidity is performed, the amount of thermal distortion of the entire plate can be significantly reduced.

[0176] The multi-structural member 200 according to the present invention is expected to have extremely excellent usefulness especially when applied to the production of the car deck of a pure car carrier (PCC) in the shipbuilding industry field, and is also effective in forming the floor structure of the ship deckhouse.

[0177] (2) Second, there is an effect of reducing the ship weight.

[0178] The unit structural member 100 according to the present invention composed of a composite material and the multi-structural member 200 manufactured by combining these can realize equivalent structural performance with a weight that is about 40 to 50% lighter than that of a conventional steel plate. Therefore, it can also greatly contribute to the weight reduction of the ship.

[0179] 3. Third Embodiment - Superimposed Structural Material

[0180] A. Structure of the Superimposed Structural Material

[0181] Note that the superimposed structural material 300 having another embodiment of the lightweight structure according to the present invention can be configured by superimposing the above-described multi-structural material 200 vertically.

[0182] Referring to FIG. 15, the superimposed structural material 300 according to the present invention can be configured in a form in which the multi-structural material 200 formed by connecting a number of unit structural materials 100 is superimposed vertically.

[0183] When the superimposed structural material 300 according to the present invention is used as the structure of a floor, ceiling, or wall, both ends along the longitudinal direction within the structure should be fixed. Therefore, it is not necessary to be structurally directly connected between the multi-structural materials 200 arranged vertically.

[0184] In addition, the superimposed structural material 300 according to the present invention can be arranged with a predetermined interval between the multi-structural materials 200 facing each other in the vertical direction. When such a structure is used as a double-floor structure, the effect of reducing interlayer noise can be further doubled.

[0185] B. Application Examples and Effects of the Superimposed Structural Material

[0186] The superimposed structural material 300 according to the present invention can be used for various applications similar to the above-described multi-structural material 200. In particular, since the superimposed structural material 300 according to the present invention includes a double-floor structure itself, it can be preferably used as the floor structure of buildings and ships where the effect of reducing interlayer noise is expected. However, the present invention is not limited thereto, and it goes without saying that it can also be utilized as the structure of the wall or roof of buildings and ships.

[0187] In addition, in the laminated structural material 300 according to the present invention, by arranging the multi-structural materials 200 in a vertically laminated manner and pre-installing various concealed pipes in the space formed therebetween, various additional functions can be easily added.

[0188] As a specific application example, referring to FIG. 16, by providing a heat insulating material (I) and heating and cooling pipes (P) in the space between the upper and lower multi-structural materials 200 that make up the laminated structural material 300, a ondol function can be easily added to the laminated structural material 200. Here, the heat insulating material (I) can be arranged only on the lower side of the heating and cooling pipes (P) so that the cold or warm heat of the heat fluid flowing through the heating and cooling pipes (P) can be successfully transmitted upward, and the periphery of the heating and cooling pipes (P) can be left as an empty space.

[0189] Normally, for the floor mortar finishing work for ondol, a process of spreading a heat insulating material on a concrete slab, installing hot water pipes thereon, and then applying finishing mortar thereon is required. Here, when applying the mortar, in order to obtain a uniform flatness, mortar containing a large amount of moisture must be used, so it takes a lot of time to harden and there are also many nuisances in the work.

[0190] However, when applying the laminated structural material 300 according to the present invention, since the multi-structural material 200 arranged on the upper part performs a structural function, no separate mortar application is required. Therefore, it is very convenient and an ondol structure and / or a floor heating and cooling structure can be easily implemented.

[0191] In addition to this, referring to FIG. 17, by adding a refractory material (R) between the multi-structural material 200 arranged at the lower part and the heat insulating material (I), it is also possible to realize the fire resistance performance of the floor without separate fire protection.

[0192] According to domestic and international floor fire resistance standards, while the temperature rise on the unheated surface of structural materials is also important, the structural stability against the occurrence of fire is being considered and examined with equal importance. More specifically, with a weight body of a certain load or more (for example, 3 kN / m 2 ) placed on top of the structural material, exposing the lower part of the structural material to a heat source, and after a certain period of time (for example, 2 hours) has passed, the structural stability is evaluated by checking the amount of deflection of the structure.

[0193] Normally, in the case of conventional building structural materials made of metal, when exposed to heat during a fire resistance test, when the temperature reaches a certain level or above, the structural performance is lost. Therefore, in order to meet the fire resistance standards, additional post - work of coating the metal lower part with fire - resistant materials is carried out.

[0194] However, as shown in FIG. 17, according to the structure of the present invention in which a fire - resistant material (R) is arranged in advance inside the superimposed structural material 300 manufactured in a modular manner, the multi - structural material 200 arranged at the lower part is exposed to the heat source due to the occurrence of a fire. Even if the structural performance is lost, the upper multi - structural material 200 protected by the fire - resistant material (R) maintains its structural performance. Therefore, the structural stability can be maintained in a fire situation without performing additional fire - resistant coating work as in the conventional case, and the above - mentioned fire resistance standards can also be easily met.

[0195] Referring to FIG. 18, the superimposed structural material 300 according to the present invention can have both edge ends along the longitudinal direction fixed to the wall of the building in a similar manner to the multi - structural material 200. When the superimposed structural material 300 is used as a floor structure, it can be arranged at an interval from the concrete slab constituting the upper floor.

[0196] At this time, the upper multi - structural material 200 and the lower multi - structural material 200 constituting the superimposed structural material 300 can be connected to the wall of the building respectively. As described above, only a part of the numerous unit structural materials 100 constituting each multi - structural material 200 can be directly fixed to the wall.

[0197] In addition, when implementing a double floor structure with the superposed structural material 300 according to the present invention, impact noise, which is a direct cause of interlayer noise, will be generated in the upper multi-structural material 200. Therefore, the upper multi-structural material 200 applies the first to fourth wall connection structures described with reference to FIGS. 10 to 13 before, and is connected to the building wall so as to enable a buffering action. The lower multi-structural material 200 can be connected to the wall through simple mechanical fastening such as bolt fastening.

[0198] When the superposed structural material 300 according to the present invention is used as a floor structure of a building, the following effects can be expected.

[0199] (1) First, it is possible to realize an ultra-lightweight long-span dry structure with far superior structural performance. When using this, the efficiency of the entire construction work can be greatly increased.

[0200] During construction, reinforced concrete floor construction is a basic skeleton construction that is the most complicated and occupies many construction periods among all construction works. In particular, it is greatly affected by the environment and is manufactured by a wet method with poor site conditions. Therefore, it is also cited as one of the most important works in terms of construction management and performance realization. Recently, in order to shorten the construction period, forcing the wet concrete slab construction has also led to major accidents.

[0201] The superposed structural material 300 presented in the present invention weighs only about 30 to 40% of that of concrete in general, but it is possible to realize a long-span structure that is much longer than the conventional reinforced concrete floor structure. Moreover, since it is constructed by a dry method, it is hardly affected by the environment, and has the advantage of significantly reducing complicated and poor on-site processes. Also, different from the wet method, the structural performance is realized immediately after installation, so the entire construction period can be greatly shortened.

[0202] (2) Second, since the double - floor structure is incorporated in the overlapping structural material 300 itself, it is possible to construct a floor structure with excellent inter - floor noise reduction effect. That is, without separately provided composite floor structural materials or impact - mitigation devices for inter - floor noise reduction, a high - performance floor structure with excellent inter - floor noise reduction effect can be realized only by its own structure.

[0203] (3) Third, there is an advantage that prior construction of various pipes, ceiling attachments, etc. can be carried out inside or below the overlapping structural material 300.

[0204] In particular, as described with reference to FIG. 16 before, since heat - insulating material (I) required for floor ondol, heating and cooling pipes (P), etc. can be easily installed as prior pipes inside the structure of the overlapping structural material 300, separate floor mortar finishing work for ondol can be omitted. Thus, the overall construction process can be greatly simplified. Also, the reaction of the floor temperature to temperature adjustment becomes faster, the structure for raising the temperature is much lighter and simpler, so it is also much more advantageous in terms of thermal efficiency.

[0205] Also, as described with reference to FIG. 17 before, according to the structure in which a refractory material (R) is additionally arranged inside the structure of the overlapping structural material 300, its own fire - resistant performance can be fully realized without a separate subsequent fire - resistant process.

[0206] The present invention is not limited to the described embodiments, and it is obvious to those with ordinary knowledge in this technical field that various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, it can be said that such modified examples or variations belong to the scope of the claims of the present invention.

Claims

1. A lightweight structure made of a composite material, comprising an upper plate made of a metallic material, a lower plate made of a metallic material disposed at a predetermined interval from the upper plate, and a core layer formed between the upper plate and the lower plate and made of a non-foamed polymer, and including a bending structure in which both ends along the width direction of the overall structure are bent downward, and including a "C"-shaped cross-sectional structure, and a multi-structure material configured by arranging a number of unit structure materials continuously in the width direction. A lightweight structure made of a composite material.

2. The unit structure material is characterized by including a flat plate portion formed in the horizontal direction and bent portions bent downward from both edge ends of the flat plate portion. A lightweight structure made of the composite material according to Claim 1.

3. The lightweight structure made of the composite material according to Claim 2, characterized in that the bent portions of the adjacent unit structure materials are structurally joined through bolt tightening or welding. A lightweight structure made of the composite material according to Claim 2.

4. The adjacent unit structure materials are spaced apart from each other at a predetermined interval, and finishing construction for forming a floor, ceiling or wall is carried out in the space between the adjacent unit structure materials. A lightweight structure made of the composite material according to Claim 2.

5. A lightweight structure made of the composite material according to Claim 3 or 4, characterized in that both edge ends along the longitudinal direction of the multi-structure material are fixed to the wall of a building to form the floor structure or ceiling structure of the building. A lightweight structure made of the composite material according to Claim 3 or 4.

6. When forming the floor structure of the building, the multi-structure material is disposed at an interval above a concrete slab constituting the basic framework of the building to form a double floor structure. A lightweight structure made of the composite material according to Claim 5.

7. A lightweight structure made of the composite material according to Claim 6, characterized in that a vibration reduction buffer material, a spring or a hydraulic device is included at the connection part between the multi-structure material and the wall, and a buffer structure capable of absorbing vibration is applied. A lightweight structure made of the composite material according to Claim 6.

8. The lightweight structure made of the composite material according to Claim 2, including a superimposed structure material configured by superimposing the multi-structure materials vertically. A lightweight structure made of the composite material according to Claim 2.

9. A lightweight structure made of the composite material according to Claim 8, characterized in that the bent portions of a pair of the multi-structure materials are arranged in a direction facing each other. A lightweight structure made of the composite material according to Claim 8.

10. Installing a heat insulating material and a heating, ventilation, and air conditioning (HVAC) pipe as pre-installed pipes in the space between the pair of multi-structural materials and modularizing them, characterized by The lightweight structure made of the composite material according to claim 9.

11. Characterized by additionally installing a refractory material between the heat insulating material and the multi-structural material The lightweight structure made of the composite material according to claim 10.

12. Characterized in that both edge ends along the longitudinal direction of the overlapping structural material are fixed to the wall of the building, and the floor structure or ceiling structure of the building is formed The lightweight structure made of the composite material according to claim 8.

13. Characterized in that both edge ends along the longitudinal direction of the upper multi-structural material and the lower multi-structural material constituting the overlapping structural material are fixed to the wall The lightweight structure made of the composite material according to claim 12.

14. When forming the floor structure of the building, a vibration reduction buffer material, a spring, or a hydraulic device is included at the connection part between the upper multi-structural material and the wall, and a buffer structure capable of absorbing vibration is applied, characterized by The lightweight structure made of the composite material according to claim 13.

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