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

Abstract

A composite material-based plate reinforcing material integrated lightweight structural material and a ship deck structure manufactured using the same are disclosed. The composite material-based plate reinforcing material integrated lightweight structural material according to the present invention basically has a plurality of protrusions formed at regular intervals on the lower surface of a flat plate portion, and functions as a plate reinforcing material. By being integrally included in the structure without a separate joining process such as welding or bolting, the protrusions are manufactured. As a result, it is ultra-lightweight and thin, yet has excellent structural performance and can be manufactured as a long-span structure. Therefore, it has the advantage of being widely applicable not only to the thin plate structure of ships but also as a construction material.

Description

Technical Field

[0001] The present invention relates to a composite material-based plate reinforcing member integrated lightweight structural member, a ship deck structure manufactured using the same, and a method for manufacturing a composite material-based plate reinforcing member integrated lightweight structural member. More specifically, when the ship is dry, it fundamentally solves the problem of thermal distortion caused by welding the upper plate and the plate reinforcing member in the manufacturing process of the mainly used steel plate structural member, greatly reduces the weight of the entire structure, simplifies the manufacturing process, and has excellent performance in terms of vibration / noise reduction. The present invention relates to a composite material-based plate reinforcing member integrated lightweight structural member, a ship deck structure manufactured using the same, and a method for manufacturing a composite material-based plate reinforcing member integrated lightweight structural member.

Background Art

[0002] Generally, the structural material mainly used in ships is a steel plate structural material made only of metal. As shown in FIG. 1, a conventional ship steel plate structural material is manufactured in a form in which a plate reinforcing member 20 made of metal is welded to an upper plate 10 made of metal. At this time, the plate reinforcing member 20 is composed of a Longitudinal girder 21 that reinforces the longitudinal structure and a Transverse frame 22 that reinforces the lateral structure.

[0003] A conventional steel plate structural material is first manufactured by joining a metal plate that serves as the upper plate 10 and then welding a plate reinforcing member 20 for longitudinal strength reinforcement at intervals of 500 to 900 mm between the frames. However, when the plate reinforcing member 20 is welded to the upper plate 10 at a close interval as in the conventional method, there are the following problems.

[0004] (1) Problem of thermal distortion due to welding

[0005] The most critical problem is the generation of thermal distortion due to welding. When welding the plate reinforcement 20, the welded part is heated to approximately 1,000 - 1,500 °C. However, during the process of the heated steel plate cooling, significant stress and distortion occur. As a result, after welding the plate reinforcement 20, bending is formed due to a deviation of several tens of millimeters (mm) per meter (m) across the entire plate, and thus, a huge amount of man-hours and costs are incurred for subsequent correction work.

[0006] In particular, in the case of structural materials for use in the car deck of a pure car carrier (PCC) or the walls of a ship's deckhouse, etc., thin plates with a thickness of about 6 - 10 mm are required for the upper plate. When the structure is formed in such a thin-walled manner, problems due to welding distortion, such as the upper plate itself cracking due to welding distortion or being so severely twisted that it is impossible to correct at all in the subsequent correction process, occur much more significantly than in other areas.

[0007] Currently, in order to prevent the occurrence of the above problems, simply using an upper plate that is much thicker than the thickness required structurally, or investing a huge amount of man-hours and costs to perform work to correct thermal distortion in the subsequent process, so there is a situation where a more fundamental solution is needed.

[0008] On the other hand, laser welding is known as a welding method that generates much less thermal distortion than arc welding or gas welding, which are commonly used in the shipbuilding field. Laser welding is a method of joining by concentrating the light energy emitted from a laser source on the workpiece to melt the base material. However, laser welding has limitations in supplying sufficient power to melt the base material, and the welding speed and weldable thickness are affected by the thermal conductivity of the metal rather than the power and the vaporization of the metal on the surface. Therefore, when applied to a thick base material, the welding efficiency is significantly reduced.

[0009] It is generally known that laser welding is possible up to 6 mm, but in reality, just when the thickness exceeds 4 mm, the speed of laser welding becomes significantly inferior. Therefore, generally, laser welding is mainly applied when the thickness of the base material is 3 mm or less. That is, in shipbuilding, it is not easy to apply laser welding even to a 6-mm steel plate, which is usually known as the thinnest structure. Also, to melt a 6-mm upper plate, a considerable amount of energy is required. At this time, ultimately, since the welded part formed quite widely cools down and the same welding distortion occurs simultaneously, there is no great merit.

[0010] (2) Problem of weight

[0011] Another disadvantage of conventional steel plate structural materials for ships is their excessive weight. Of course, the steel plate structural materials mainly used in ships are much lighter than construction steel-reinforced concrete. However, in terms of the importance of environmentally friendly ships, cost reduction, and labor cost reduction, which have been attracting attention in recent years, "weight reduction of ships" is one of the most significant topics globally in the shipbuilding and shipping fields. When the weight of a ship decreases, the energy required for the ship's propulsion decreases, so the carbon emissions can also be reduced. Also, weight reduction of ships is very important in terms of ensuring the ship's resilience.

[0012] Especially in the case of a pure car carrier (PCC) with several decks, due to the weight of the decks themselves, the center of gravity of the ship's weight moves upward, which causes a problem of significantly damaging the ship's resilience. Therefore, it can be said that reducing the weight of the decks and achieving weight reduction of the ship is the most important structure required.

[0013] (3) Problem of inferior utilization as a building structural material

[0014] The above-described conventional iron plate structural materials are much lighter than reinforced concrete and can achieve equivalent structural performance with a thinner profile. However, in the construction field, they are not widely used. The most significant reason is precisely the characteristic that the noise of the iron plate is transmitted. Since the entire structure of the iron plate structural material is composed of a single metal with high density, when it is subjected to impact, it has a superior noise transmission ability compared to any structural material made of other materials. Therefore, it is hardly used as building materials, especially as floor materials for buildings where prevention of inter-floor noise is important.

[0015] Also, the iron plate structural material is not suitable as a building material where heat insulation is important in terms of having too high a thermal conductivity. The thermal conductivity of reinforced concrete is 1.6 - 2.0 W / mK, while the thermal conductivity of an iron plate is as high as 83 W / mK. Having a high thermal conductivity means that external heat is transmitted very quickly and easily to the interior, which means it is very vulnerable in terms of heat insulation.

Summary of the Invention

Problems to be Solved by the Invention

[0016] An object of the present invention is to overcome the above-described technical limitations and provide a high-performance / multi-functional composite material-based plate reinforcement integrated lightweight structural material that can be effectively applied to the structure of thin plates of ships and can also be generally applied in the construction field (especially, the floor structure of buildings).

[0017] More specifically, the present invention can solve the problem of thermal distortion caused by welding of conventional ship iron plate structural materials by eliminating the joining process of the lower plate reinforcement required for conventional ship iron plate structural materials. It is possible to achieve structural weight reduction as it is much lighter compared to conventional ship iron plate structural materials and other certain structural materials, and the technical problem is to provide a composite material-based plate reinforcement integrated lightweight structural material that can also be applied in the construction field.

[0018] In addition, while being based on a composite material, the present invention can have an upper plate with a thickness similar to that of a general ship steel plate structure material, and the form and assembly method are similarly embodied to those of a general ship steel plate structure material, and it can be easily utilized as a ship structure. In particular, it aims to provide a composite material-based plate reinforcement integrated lightweight structure material that can be used for manufacturing a deck structure of a ship such as a pure car carrier (PCC).

[0019] The technical problems of the present invention are not limited to the above-mentioned technical problems, and other technical problems not mentioned can be clearly understood by a person skilled in the art from the following description.

Means for Solving the Problems

[0020] According to one aspect of the present invention for achieving the above object, it includes an upper plate made of a flat metal material, a horizontal plate formed in the horizontal direction, and a vertical plate bent downward from the horizontal plate. A plurality of reinforcing plates made of a metal material are arranged at a predetermined interval below the upper plate, and a non-metal core layer is formed in the space between the upper plate and the reinforcing plates and in the space between the adjacent reinforcing plates. The plurality of vertical plates are formed in pairs, with those facing each other closely adjacent to each other. A pair of vertical plates and the core layer formed therebetween constitute a protrusion that functions as a plate reinforcement. The protrusions are formed at regular intervals along the horizontal direction and extend while maintaining a constant cross-sectional shape along the longitudinal direction. A composite material-based plate reinforcement integrated lightweight structure material can be provided.

[0021] The core layer can be formed of a non-foaming polymer.

[0022] The horizontal plate and the vertical plate constituting the reinforcing plate can be formed by bending a single plate material.

[0023] The lower end of the protruding portion is bent again, or a separate metal finishing material is joined to the lower end of the protruding portion, and the lower end of the protruding portion is configured to have an "L"-shaped cross section or a "⊥"-shaped cross section. A vertical reinforcing portion formed in the vertical direction from the protruding portion performs the web function of the plate reinforcing material, and a vertical reinforcing portion formed in the horizontal direction from the protruding portion can perform the flange function of the plate reinforcing material.

[0024] Among the plurality of reinforcing plates, the remaining reinforcing plates except for the reinforcing plates arranged at both edge ends along at least the width direction have an "ロ"-shaped cross section, and further include a lower plate disposed at a predetermined interval below the reinforcing plate. An additional core layer is further formed between the reinforcing plate and the lower plate, and a composite material-based plate reinforcing material integrated lightweight structural material according to one aspect of the present invention can be manufactured to include an overall ladder shape.

[0025] A high-performance heat insulating material having a thermal conductivity of 0.02 W / mK or less can be additionally disposed in the core layer.

[0026] The high-performance heat insulating material may be a vacuum insulating panel (VIP).

[0027] A composite material-based plate reinforcing material integrated lightweight structural material according to one aspect of the present invention may further include a side end finishing material for finishing both edge ends of the upper plate and the reinforcing plate. The side end finishing material is inserted between the upper plate and the reinforcing plate, but can be pushed in by a predetermined distance from the edge ends of the upper plate and the reinforcing plate.

[0028] When connecting the lightweight structural materials adjacent to each other, the upper plates facing each other and the lower plates facing each other are joined by welding, and a non-foaming polymer stock solution is injected into the space formed between the upper plate, the lower plate, and the side end finishing material and cured, whereby the connection portion can be finished airtight.

[0029] The composite material-based plate reinforcement integrated lightweight structural material according to one aspect of the present invention may further include side end finishing materials for finishing both edge ends of the upper plate and the reinforcement plate. The side end finishing materials are provided in an angle form having a cross-section of one of a straight shape or an inverted "L" shape, with one end inserted between the upper plate and the reinforcement plate and the other end protruding outside the upper plate and the reinforcement plate.

[0030] When connecting the lightweight structural materials adjacent to each other, the side end finishing materials facing each other can be structurally joined by welding or bolting.

[0031] Also, in order to achieve the above object, the present invention can provide a ship deck structure manufactured using a lightweight structural material including at least one of the above-described features.

[0032] Here, the ship may be a pure car carrier (PCC).

[0033] According to another aspect of the present invention for achieving the above object, in a method of manufacturing a lightweight structural material including an upper plate made of a flat metal material, a plurality of reinforcement plates made of a metal material including a horizontal plate disposed at a predetermined interval below the upper plate and formed in a horizontal direction and a vertical plate bent downward from the horizontal plate, and a core layer formed in a space between the upper plate and the reinforcement plate and in a space between adjacent reinforcement plates, a step of filling a non-foaming polymer stock solution into the space between the upper plate and the reinforcement plate and into the space between adjacent reinforcement plates, a step of curing the non-foaming polymer stock solution, and a step of completing the formation of the core layer when the non-foaming polymer stock solution is cured can be provided as a method of manufacturing a composite material-based plate reinforcement integrated lightweight structural material.

[0034] At the stage of filling the non-foaming polymer stock solution, a space is formed on the upper plate. After pouring the non-foaming polymer stock solution, with the reinforcing plate in an inverted state, it is charged from above and pressurized until it reaches a position with a predetermined fixed interval from the upper plate. Thus, due to the force exerted by the reinforcing plate, the non-foaming polymer stock solution can melt into the space between the reinforcing plate and be evenly filled while overcoming the frictional resistance due to viscosity.

[0035] The amount of the non-foaming polymer stock solution initially poured into the space on the upper plate is charged in an amount at least 2% more than the actual volume occupied by the core layer. The excess can be extruded outwards and discharged by the force exerted by the reinforcing plate.

[0036] At the stage of filling the non-foaming polymer stock solution, the space where the core layer is formed is sealed, and the non-foaming polymer stock solution is injected into the sealed space using an injection pipe. However, the injection pipe can be divided into several small pipes and arranged in the sealed space.

[0037] At the stage of filling the non-foaming polymer stock solution, the space where the core layer is formed is sealed, an injection pipe is inserted into one side of the sealed space, and while injecting the non-foaming polymer stock solution, on the other side, air in the sealed space can be inhaled using a vacuum pump.

[0038] At least in one of the stage of filling the non-foaming polymer stock solution and the stage of curing the non-foaming polymer stock solution, for the purpose of maintaining flatness and an accurate angle, a magnet is arranged on at least one of the upper plate and the reinforcing plate, or it can be adsorbed by a vacuum adsorption device to apply a tensile force.

Advantages of the Invention

[0039] The composite material-based plate reinforcement integrated lightweight structural material according to the present invention can be effectively applied to the thin plate structure of ships. Of course, it can also be generally applied in the construction field (especially, construction floor structures), and specifically has the following effects.

[0040] (1) By eliminating the joining process of the lower plate reinforcement required for conventional ship steel plate structural materials, the thermal distortion problem caused by welding of conventional ship steel plate structural materials can be fundamentally solved.

[0041] (2) The composite material-based plate reinforcement integrated lightweight structural material according to the present invention is extremely light in weight compared to any other structural material including conventional ship steel plate structural materials, and it is possible to achieve structural weight reduction. That is, when used as the structure of a ship or a building, it has the effect of reducing the total weight of the structure.

[0042] (3) The composite material-based plate reinforcement integrated lightweight structural material according to the present invention can be manufactured with a thickness similar to that of general ship steel plate structural materials while being based on a composite material. Since the form and assembly method are similar to those of general ship steel plate structural materials, it can be easily used in the manufacture of ship structures. Preferably, the composite material-based plate reinforcement integrated lightweight structural material according to the present invention can be utilized as a deck structure of a ship, and it is expected to be extremely useful when used in the manufacture of a deck structure of a pure car carrier (PCC) where weight reduction of the ship is required more importantly than anything else.

[0043] (4) The composite material-based plate reinforcement integrated lightweight structural material according to the present invention can be manufactured as a structure with a significantly thinner thickness among the structural materials based on composite materials, and it can be manufactured at a lower cost compared to the general steel plate structural materials used in conventional ships. Therefore, it also has advantages in terms of cost.

[0044] (5) The lightweight structural material integrated with a plate reinforcing material based on a composite material according to the present invention can basically reduce noise and vibration and also has heat insulation performance by being manufactured from a composite material of metal and polymer. Therefore, it has the advantage of being applicable not only in the ship field but also as a construction structural material. Further, when applied in the construction field, by superposing and arranging the lightweight structural materials according to the present invention and adding functions such as cold / hot and fire resistance to the space therebetween, there is also an effect that a multifunctional structure can be realized.

[0045] The effects of the present invention are not limited to the effects described above, and other effects not mentioned can be clearly understood by ordinary technicians from the following materials.

Brief Description of the Drawings

[0046]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Figure 24

Figure 25

MODE FOR CARRYING OUT THE INVENTION

[0047] Details regarding the object, technical configuration, and the resulting actions and effects of the present invention will be more clearly understood through a detailed description based on the drawings attached to the specification of the present invention.

[0048] The terms used in this specification are merely used for explaining specific embodiments and are not intended to limit the present invention. For example, terms such as "configured to" or "including" used in this specification should not necessarily be construed as necessarily including several components or several steps described in the invention, and it should not be construed as not including some of those components or some of those steps, or being further able to include additional components or steps. Also, the singular expressions used in this specification include plural expressions that do not have clearly different meanings in the context.

[0049] Hereinafter, with reference to the attached 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. Of course, the embodiments of the present invention can have various applications for ordinary technicians in the art.

[0050] I. Structure of the lightweight structural material

[0051] The lightweight structural material 100 according to the present invention basically includes an upper plate 110 made of a metal material, a reinforcing plate 120 made of a metal material, and a core layer 140 made of a non-metal material formed therebetween, and can be composed of a composite material of metal and non-metal. The downward bending structure of the reinforcing plate 120 and the protruding structure formed by the core layer 140 formed vertically therebetween are characterized by functioning as a plate reinforcing material.

[0052] The lightweight structural material 100 according to the present invention can have several embodiments according to the form of the downward protrusion and the manufacturing method. Hereinafter, with reference to FIGS. 2 to 6, the possible forms of the lightweight structural material 100 according to the present invention will be examined one by one.

[0053] (1) First Embodiment

[0054] Referring to FIG. 2, let's look at the first embodiment, which is the most basic form of the lightweight structural material 100 according to the present invention. Referring to FIG. 2, the lightweight structural material 100 according to the first embodiment of the present invention includes an upper plate 110 made of a flat metal material, a reinforcing plate 120 made of a metal material that is arranged at a certain interval below the upper plate 110 and includes a structure bent downward to function as a plate reinforcing material, and a non-metallic core layer 140 formed in the space between the upper plate 110 and the reinforcing plate 120 and in the space between the adjacent reinforcing plates 120.

[0055] The upper plate 110 can be provided in the form of a square plate having a predetermined thickness.

[0056] The reinforcing plate 120 can be configured in such a form that a plate having a predetermined thickness is bent one to two times, and a downward bending structure can be formed by a portion bent vertically from a horizontally formed plate.

[0057] The reinforcing plate 120 can be separately manufactured in a plurality of configurations. The reinforcing plate 120 can include a first reinforcing plate 120a having an inverted L-shaped cross section and a second reinforcing plate 120b having a C-shaped cross section. The first reinforcing plate 120a is arranged at both ends along the width direction of the lightweight structural material 100, and at least one or more second reinforcing plates 120b can be repeatedly arranged therebetween. And the adjacent first reinforcing plate 120a and second reinforcing plate 120b are arranged such that the legs arranged vertically face each other at a predetermined interval.

[0058] The core layer 140 may be formed in the space formed between the upper plate 110 and the reinforcing plate 120, and in the space between adjacent reinforcing plates 120. The core layer 140 may be formed of a non-foaming polymer, more preferably a non-foaming polyurethane having suitable elasticity and structural strength, and the core layer 140 may be formed by hardening a non-foaming polymer concentrate filled in the space, as described below.

[0059] The completed lightweight structural material 100 includes a flat plate portion formed in the horizontal direction and a protruding portion protruding downward from the lower surface of the flat plate portion, and may have a structure in which two or more protruding portions are repeatedly formed at regular intervals. Here, when a floor structure such as a deck is constructed using the lightweight structural material 100, the flat plate portion serves as a structural member that is in primary contact with the design load, and the protruding portion can function as a plate reinforcement material that enhances structural performance and prevents buckling by increasing the strength and rigidity of the flat plate portion formed in the horizontal direction.

[0060] More specifically, in the lightweight structural material 100, the protrusions can be composed of legs of the reinforcing plate 120 arranged opposite each other and a core layer 140 filling the space between them, and such a protruding structure can perform the function of the web of the plate reinforcement material.

[0061] Meanwhile, when the reinforcing plate 120 is configured in a bent shape of the character “￢” or “匚”, it is preferable to bend the metal plate constituting the reinforcing plate 120 by bending. This is to realize a structure that is structurally strong and does not have the risk of thermal distortion or cracks due to welding by making the flat plate portion formed in the horizontal direction and the protruding portion formed in the vertical direction of the lightweight structural material 100 have a continuous shape without being interrupted.

[0062] (2) Second embodiment

[0063] The second embodiment of the lightweight structural member 100 according to the present invention shown in FIG. 3 has the same completed structure as the aforementioned first embodiment. However, the second embodiment differs from the first embodiment in that a large number of reinforcing plates 120 are manufactured in the same shape having a substantially "T" - shaped cross - section, and the adjacent reinforcing plates 120 are connected by laser welding.

[0064] At this time, the reinforcing plate 120 is configured to include a space where the core layer 140 can be filled in a portion protruding downward. Thus, a total of four bending processes are performed on one reinforcing plate 120.

[0065] Such a second embodiment requires more labor in that the bending process of the reinforcing plate 120 has to be performed more times compared to the first embodiment. However, since the reinforcing plate 120 manufactured in the "T" shape already includes a protruding structure and the lower end of the protruding structure is in a closed form, it can be more structurally stable. Also, the operation of forming the core layer 140 described later can be performed more smoothly.

[0066] (3) Third Embodiment

[0067] Referring to FIG. 4, the lightweight structural member 100 according to the third embodiment of the present invention can have a structure in which the lower end portion of the protruding portion protruding downward is bent again in the horizontal direction. That is, in the lightweight structural member 100, the protruding portion protruding downward has a substantially "L" - shaped cross - section.

[0068] Thereby, in the third embodiment, the protruding portion protruding downward of the lightweight structural member 100 can include a vertical reinforcing portion formed in the vertical direction and a horizontal reinforcing portion formed in the horizontal direction. The vertical reinforcing portion can perform the web function of the plate reinforcing material, and the horizontal reinforcing portion can perform the flange function of the plate reinforcing material.

[0069] On the other hand, FIG. 4 shows a structure finished with the core layer 140 exposed at the edge of the horizontal reinforcing portion formed at the lower end of the protruding portion, but this portion may be configured as a structure closed by the reinforcing plate 120 in the same manner as in the second embodiment described above.

[0070] (4) Fourth Embodiment

[0071] Referring to FIG. 5, the lightweight structural member 100 according to the fourth embodiment of the present invention can be configured such that the lower end portion of the protruding portion protruding downward extends along both sides in the horizontal direction and has a substantially "⊥"-shaped cross-sectional structure.

[0072] In the fourth embodiment, the protruding portion protruding downward of the lightweight structural member 100 can include a vertical reinforcing portion formed in the vertical direction and a horizontal reinforcing portion formed in the horizontal direction. It is similar to the third embodiment described above that the vertical reinforcing portion can perform the web function of the plate reinforcing material and the horizontal reinforcing portion can perform the flange function of the plate reinforcing material.

[0073] The lightweight structural member 100 according to the third and fourth embodiments can perform a more effective plate reinforcing material function because the sectional modulus is increased more significantly by adding the form of the lower edge of the protruding portion.

[0074] (5) Fifth Embodiment

[0075] Referring to FIG. 6, as another embodiment, the fifth embodiment of the lightweight structural member 100 according to the present invention includes an upper plate 110 made of a flat metal material, a lower plate 130 made of a flat metal material arranged in parallel with the upper plate 110 at a position spaced apart from the lower side of the upper plate 110 at a certain interval, a plurality of reinforcing plates 120 arranged between the upper plate 110 and the lower plate 130, and a non-metallic core layer 140 formed in the space between the lower plate 130 and the spaces between adjacent reinforcing plates 120, and can be configured in a substantially ladder-like form.

[0076] The reinforcing plate 120 may be spaced apart from the upper plate 110 at a certain distance so that a space is formed between the reinforcing plate 120 and the upper plate 110, and may also be spaced apart from the lower plate 130 at a certain distance.

[0077] In the fifth embodiment, the reinforcing plate 120 may include a first reinforcing plate 120c having a cross section in the shape of a letter "X" and a second reinforcing plate 120d having a cross section in the shape of a letter "K", and the first reinforcing plate 120c may be disposed at both ends in the width direction of the lightweight structural material 100, and at least one or more second reinforcing plates 120d may be repeatedly disposed therebetween. The intervals between the first reinforcing plate 120c and the second reinforcing plate 120d and between the adjacent second reinforcing plates 120d may be the same.

[0078] The core layer 140 may be formed in the spaces between the upper plate 110 , the reinforcing plate 120 and the lower plate 130 , and in the spaces between adjacent reinforcing plates 120 , so that the reinforcing plate 120 is surrounded by the core layer 140 .

[0079] In the lightweight structural material 100 according to the fifth embodiment of the present invention, the portion formed vertically by the reinforcing plate 120 and the core layer 140 functions as the web of the plate reinforcement material, and the structure of the core layer 140 formed horizontally between the reinforcing plate 120 and the lower plate 130 and the lower plate 130 attached to its lower end functions as the flange of the plate reinforcement material.

[0080] In the lightweight structural material 100 according to the present invention including the first to fifth embodiments, the downwardly projecting protrusions (in the fifth embodiment, the parts formed in a vertical columnar shape by the opposing reinforcing plates 120 and the core layer 140 formed therebetween can be seen as protrusions) act to increase the section modulus of the entire structure. The section modulus can be determined by the height, shape, etc. of the protrusions that function as a plate reinforcing structure.

[0081] A conventional steel plate structural member (see Fig. 1) composed only of metals mainly applied to ship structures has a plate reinforcing member 20 welded to the lower surface of the upper plate 10 for structural reinforcement. It has been explained in the background art that such a conventional method has a problem that considerable thermal distortion occurs when the plate reinforcing member 20 is connected by welding.

[0082] However, different from the conventional steel plate structural member in which the upper plate 10 and the plate reinforcing member 20 that function as structural members are separately manufactured and then joined by welding, the lightweight structural member 100 according to the present invention is integrally manufactured with a flat plate portion and a protruding portion protruding therefrom, and is configured in a form already included in the plate reinforcing structure itself. Therefore, there is no possibility of generating the problem of thermal distortion due to welding as in the conventional case.

[0083] Also, when manufacturing a conventional steel plate structural member, even if we assume a case where the upper plate 10 and the plate reinforcing member 20 are bolted together without welding, additional hole construction and local structural reinforcement work for bolted connection between the upper plate 10 and the plate reinforcing member 20 are required. In contrast, the lightweight structural member 100 according to the present invention in which the plate reinforcing structure is integrally formed does not require any of the above additional processes, and thus can have structurally stable performance.

[0084] Moreover, since the lightweight structural member 100 according to the present invention itself already has a plate reinforcing structure by the protruding portion, compared with the case where a welded connection of the plate reinforcing structure is required, the thicknesses of the upper plate 110 and the reinforcing plate 120 can be formed in a much thinner structure, and it is possible to manufacture an optimized composite structure.

[0085] In particular, the lightweight structural member 100 according to the present invention is characterized in that not only the flat plate portion but also the protruding portion that functions as a plate reinforcing member is composed of a composite material (metal + polymer) that is not a single metal material. According to such a structure of the present invention, there is an advantage that the structural weight can be reduced by about 40 to 50% compared with the case of using a plate reinforcing member made only of metal.

[0086] The thicknesses of the upper plate 110, the reinforcing plate 120, the lower plate 130, and the core layer 140 that constitutes the internal core of the lightweight structural material 100 according to the present invention can be designed to such an extent that the lightweight structural material 100 according to the present invention can achieve structural performance equivalent to the structural strength of a general ship steel plate structural material.

[0087] Specifically, the thicknesses of the upper plate 110 and the reinforcing plate 120 of the lightweight structural material 100 according to the present invention can be formed to be 0.4 to 20 mm respectively. At this time, as will be described later, when the lightweight structural materials 100 according to the present invention are joined together as individual modules or when they are to be connected to any other structure, welding operations may have to be performed. Therefore, the thicknesses of the upper plate 110 and the reinforcing plate 120 that constitute the outer plate of the lightweight structural material 100 are preferably formed to be 0.4 mm or more for easy laser welding. Also, in order to achieve the structural weight reduction which is one of the technical problems of the present invention, the thicknesses of the upper plate 110 and the reinforcing plate 120 are preferably formed to be 10 mm or less. Thus, the present invention presents 0.4 to 10 mm as a more preferable thickness of the metal plates that constitute the upper plate 110 and the reinforcing plate 120. When further including the lower plate 130 as in the fifth embodiment, the thickness of the lower plate 130 follows the thickness of the upper plate 110.

[0088] The thickness of the core layer 140 of the lightweight structural material 100 according to the present invention can be configured in various ways up to 3 to 40 mm. At this time, the core layer 140 may have different thicknesses for the portion formed in the horizontal direction and the portion formed in the vertical direction (the portion formed between the mutually opposing reinforcing plates 120).

[0089] That is, in the lightweight structural material 100 according to the present invention, the thickness of the core layer 140 in the flat portion and the thickness of the core layer 140 in the protruding portion may be formed to be the same, but they can also be adjusted differently. When trying to form different thicknesses, it is preferable to form the thickness of the core layer 140 of the protruding portion that functions as a plate reinforcing material to be thinner than the thickness of the core layer 140 of the flat portion.

[0090] On the one hand, there are things that should not be confused by the names of the members as described above. However, it does not mean that the upper plate 110 of the lightweight structural material 100 according to the present invention must have the same structural performance as the upper plate 10 of a general ship iron plate structural material alone. In the lightweight structural material 100 according to the present invention, it should be understood that it includes the upper plate 110, the reinforcing plate 120, and the core layer 140 formed therebetween, and the flat plate portion formed in the horizontal direction and directly contacting the design load can be designed to have the same structural performance as the upper plate 10 of a general ship iron plate structural material. This is the same when determining the thickness of the reinforcing plate 120 constituting the plate reinforcement structure and the core layer 140 formed therebetween.

[0091] That is, in the lightweight structural material 100 according to the present invention, the entire flat plate portion including the upper plate 110, the reinforcing plate 120, and the core layer 140 formed therebetween is corresponded to the upper plate 10 of a general ship iron plate structural material, and the structural strength must be considered. Therefore, the thickness of the upper plate 110 in the lightweight structural material 100 according to the present invention, which is designed to have the same structural performance as a general ship iron plate structural material, will be much thinner than the upper plate 10 in the corresponding general ship iron plate structural material. For example, the composite structure of the lightweight structural material 100 according to the present invention equivalent to the 6-mm upper plate 10 of a general ship iron plate structural material can be formed by an upper plate 110 with a thickness of 1 mm, a core layer 140 with a thickness of 5 mm, and a reinforcing plate 120 with a thickness of 1 mm.

[0092] Also, in the lightweight structural material 100 according to the present invention, the interval (d) between the protruding structures serving as the web and / or flange structure of the plate reinforcement can be formed in the range of 200 to 3,000 mm. More preferably, the interval (d) between the protruding portions of the lightweight structural material 100 according to the present invention may be formed at approximately 600 to 900 mm, which is similar to that of a general ship iron plate structural material. If the thin-walled structure of the lightweight structural material 100 is abandoned (for example, when the thickness increases due to the arrangement of the high-performance heat insulating material 141 inside the core layer 140 as described later), the interval (d) between the protruding structures can be increased to 1,500 to 3,000 m.

[0093] The width of the lightweight structural member 100 according to the present invention can be changed according to the number of protrusions formed. For example, when the interval between protrusions is uniform at 700 mm, in the case of a structure having 3 to 4 protrusions, the width of the entire plate can be formed to be approximately 2,100 to 3,500 mm.

[0094] The height (h) of the protrusion protruding downward from the lightweight structural member 100 can be formed at a level having a structural performance equivalent to that of a general ship steel plate structural member by comparing the section modulus of the entire structure, and can be made similar to or lower than that of a conventional plate reinforcement made only of metal. For example, if the height of the plate reinforcement of a conventional steel plate structural member for embodying equivalent performance is 100 mm, the height (h) of the protrusion of the lightweight structural member 100 according to the present invention can also be formed at a similar level. However, as described above, as the shape of the protrusion is added from the simple linear form of "l" to the forms of "L", "⊥", and ladder shape, the section modulus of the entire structure increases, and therefore, the height (h) of the protrusion can be further reduced. Here, the height (h) of the protrusion can mean the height from the lowermost end of the reinforcing plate 120 to the lower surface of the reinforcing plate 120 forming the flat plate portion formed in the horizontal direction.

[0095] Also, as in the third and fourth embodiments (see FIGS. 4 and 5), when the lightweight structural member 100 according to the present invention is further configured to include a horizontal reinforcing portion formed in the horizontal direction at the lower end of the protrusion, the width (w) of the horizontal reinforcing portion can also be formed at an equivalent size similar to that of a plate reinforcement for a conventional steel plate structural member as described above.

[0096] When the thickness, width, height, etc. of each component are designed within the range presented above, the lightweight structural material 100 according to the present invention can be manufactured as a long-span structure with a length starting from approximately 3 m and reaching a maximum length of 14 m. The reason why the lightweight structural material 100 according to the present invention can be manufactured as a long-span structure with a maximum length of 14 m is that the core layer 140, 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 reinforcing plate 120. While having the basic structural performance, the protruding portions protruding downward from the lightweight structural material 100 function as plate reinforcing materials.

[0097] Also, here, the point to note is that the lightweight structural material 100 according to the present invention manufactured as a long-span structure can exhibit structural performance equivalent to or better than that of general ship steel plate structural materials or building reinforced concrete in the direction across the width of the structural material without adding separate reinforcing materials. That is, in the general ship steel plate structural material shown in FIG. 1, the plate reinforcing material 20 should be configured to include both the Longitudinal girder 21 that reinforces the longitudinal structure and the Transverse frame 22 that reinforces the transverse structure. However, for the lightweight structural material 100 according to the present invention, it is sufficient to form a large number of protruding portions only along the longitudinal direction at the lower part of the plate structure, and there is no need to provide a separate reinforcing structure along the width direction across it.

[0098] The lightweight structural material 100 according to the present invention can be manufactured to meet a predetermined deflection amount standard. Such a deflection amount standard can be satisfied by adjusting / selecting the height and shape of the protruding portions that function as plate reinforcing materials as described above to form the section modulus of the entire structure at a predetermined level or higher.

[0099] As an example, when the total length of the lightweight structural material 100 according to the present invention is 6 m, the thicknesses of the upper plate 110 and the reinforcing plate 120 are each formed to be 1 mm, and the core layer 140 is formed as a 5-mm-thick thin core, with a live load of 200 kgf / m 2And while forming the distance between the protrusions to 600 mm under the condition of both ends being fixed, in order to satisfy the deflection amount standard of L / 480, the height (h) of the protrusion can be calculated to be approximately 125 mm in the case of the "l" shape, approximately 100 mm in the case of the "⊥" shape where a horizontal reinforcing portion with a width (w) of 100 mm is formed, and approximately 65 mm in the case of the ladder shape.

[0100] In the said deflection amount standard, "L" means the length (span) of the lightweight structural member 100. In order to satisfy the L / 480 deflection amount standard, the central portion of the lightweight structural member 100 shall not deflect by more than 1 / 480 of the total length of the lightweight structural member 100. As in the example mentioned above, when the lightweight structural member 100 according to the present invention is manufactured with a length (span) of 6 m and both ends are fixed, it can satisfy the L / 480 deflection amount standard only when the maximum deflection amount is generated at 6,000 / 480 = 12.5 (mm) or less.

[0101] That is, the structural performance of the lightweight structural member 100 for satisfying the deflection amount standard can be realized through adjustment of the height, shape, etc. of the protrusion. Also, by imparting an adhesive strength above a certain level between the upper plate 110, the reinforcing plate 120, and the core layer 140, it is possible to further assist in realizing the structural performance of the lightweight structural member 100 as described above.

[0102] Specifically, the non-foaming polymer constituting the core layer 140 has an adhesive force by itself. As will be described later, during the process of the liquid non-foaming polymer stock solution hardening, the surfaces in contact with the upper plate 110 and the reinforcing 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 140, and between the reinforcing plate 120 and the core layer 140. When further including the lower plate 130 as in the fifth embodiment, the same adhesive strength can also be imparted between the lower plate 130 and the core layer 140.

[0103] As will be described later, the lightweight structural member 100 according to the present invention can be finished at its side ends or lower end with finishing members made of non-metal or metal materials for future structural connection with other modules or for the purpose of optimizing the structural strength required by the module itself or reinforcing it in terms of fatigue strength. Even in this case, it is preferable to impart a bonding strength of at least 1 MPa (more preferably, 6 MPa or more) between the non-foamable polymer that is the internal core and the finishing material.

[0104] As described above, in addition to the material characteristics of the lightweight structural member 100 according to the present invention, which is composed of a composite material of the upper plate 110 and the reinforcing plate 120 made of metal material and the core layer 140 made of non-foamable polymer, the lightweight structural member 100 itself is configured to include a plate reinforcement structure, whereby it is possible to realize an ultra-lightweight and significantly excellent structural performance.

[0105] Specifically, the lightweight structural member 100 fabricated from the composite material according to the present invention can realize equivalent structural performance with a weight approximately 50 to 60% that of a general iron plate structural member mainly used in the ship field, and can realize equivalent structural performance with a weight approximately 15 to 25% that of reinforced concrete mainly used in the construction field.

[0106] Also, according to a general standard carbon emission table, an iron plate and a non-foamable polymer are known to generate 2 to 3 kg of CO2 per kilogram (kg). However, since the specific gravity of the non-foamable polymer is at a level of 0.8 to 1.8, which is much lower than the specific gravity of 7.85 of the iron plate, the carbon emissions generated during the structural manufacturing process are significantly reduced, and the carbon emissions can be reduced by approximately 50% compared to the conventional case.

[0107] II. Finishing and Connecting Structure of Lightweight Structural Member

[0108] Hereinafter, with reference to FIGS. 7 to 11, the finishing and connecting structure of the lightweight structural member 100 according to the present invention will be described.

[0109] (1) First Side End Finishing and Connecting Structure

[0110] First, referring to FIG. 7, in the lightweight structural member 100 according to the present invention, a first side end finishing member 151 made of a metal or non-metal material can be inserted and disposed between the upper plate 110 and the reinforcing plate 120 at both edge ends formed in the horizontal direction. Here, when the first side end finishing member 151 is made of a non-metal material, it is preferably made of a material capable of achieving a bonding strength of at least 1 MPa (more preferably, 6 MPa or more) with the non-foaming polymer which is the inner core.

[0111] Then, the lightweight structural members 100 adjacent to each other can be joined by laser welding of the upper plates 110 and the reinforcing plates 120 arranged to abut against each other. As described above, laser welding has the advantage of less thermal distortion, but as a problem that the efficiency deteriorates as the thickness increases, there has been a problem that it is not easy to apply to general steel plate structural members for ships with a thickness of 6 mm or more. However, in the present invention, since metal plates with a level thinner than 6 mm (for example, 0.5 to 5 mm) are used as the upper plate 110 and the reinforcing plate 120, there is an advantageous aspect suitable for laser welding.

[0112] Also, in the present embodiment, the first side end finishing member 151 can be disposed by being pushed into the inside of the lightweight structural member 100 by a predetermined distance. According to this, in order to connect two or more lightweight structural members 100, when the lightweight structural members 100 adjacent to each other are arranged to abut against each other, a space (S) may be formed between the first side end finishing members 151 arranged on each lightweight structural member 100. By injecting a non-foaming polymer stock solution (more preferably, a non-foaming polyurethane stock solution) into the space (S) and curing it, the connection part of the lightweight structural members 100 adjacent to each other can be finished in a sealed manner. At this time, an additional effect of imparting an additional bonding force between the lightweight structural members 100 by the adhesive force of the non-foaming polymer itself can also be achieved.

[0113] On the one hand, the first side end finishing material 151 may be removed, and the non-foaming polymer that is the core layer 130 may be left exposed as it is. However, even in this case, a predetermined space (S) may be formed at the portion where the lightweight structural material 100 is connected, and the non-foaming polymer stock solution may be injected into the space (S) and the method of finishing it secretly may be similarly applied, which goes without saying.

[0114] (2) Second side end finishing and connection structure

[0115] Next, referring to FIG. 8, in the lightweight structural material 100 according to the present invention, a second side end finishing material 152 provided with a metal material can be inserted and arranged at both edge ends formed in the horizontal direction.

[0116] In this embodiment, the second side end finishing material 152 can be provided with a metal plate having a cross-section in the shape of a single line and having a thickness corresponding to the core layer 140. One end portion can be inserted into the lightweight structural material 100, and the other end portion can protrude and be exposed outside the lightweight structural material 100.

[0117] The second side end finishing material 152 protruding to the outside can be structurally coupled to the second side end finishing material 152 provided on the side of another adjacent lightweight structural material 100 by welding or bolting. When the side end portion of the lightweight structural material 100 is finished with a metal material having a predetermined thickness as in this embodiment, a common welding such as CO2 welding can be applied, and in addition to welding, a mechanical coupling method using bolts or the like can be applied, which has the advantage of excellent design flexibility. (3) Third side end finishing and connection structure

[0118] Referring to FIG. 9, in the lightweight structural material 100 according to the present invention, a third side end finishing material 153 provided with a metal material can be inserted and arranged at both edge ends formed in the horizontal direction.

[0119] The third-side end finishing and connection structure of the lightweight structural member 100 according to the present invention is similar to the second-side end finishing and connection structure described immediately above. However, unlike the case where the above-described second-side end finishing member 152 is simply provided in a single straight shape, there is a difference in that the third-side end finishing member 153 is provided in an angle form having a "¬" shaped cross section.

[0120] According to this embodiment, when attempting to connect two or more lightweight structural members 100 finished with the third-side end finishing member 153, the third-side end finishing members 153 provided on each of the mutually adjacent lightweight structural members 100 can be structurally joined by welding or bolt tightening or the like in a state where they are in contact with each other (it is also possible to apply both welding and bolt tightening connections). When the cross section of the third-side end finishing member 153 is provided in a "¬" shape as in this embodiment, since there are legs, it can be regarded as a structure that is easier to apply the bolt tightening connection method.

[0121] (4) Lower end finishing structure

[0122] On the other hand, for structural efficiency, in the lightweight structural member 100 according to the present invention, the lower end of the protruding portion that functions as a plate reinforcing member can also be finished and reinforced as a metal structure.

[0123] More specifically, the first lower end finishing member 154 having an "L" shaped cross section shown in FIG. 10 or the second lower end finishing member 155 having a "⊥" shaped cross section shown in FIG. 11 can be inserted and joined to the lower end of the protruding portion. However, when the lower end of the protruding portion of the lightweight structural member 100 according to the present invention is already manufactured in a closed state, starting from the second embodiment shown in FIG. 3, it is not necessary to apply the lower end finishing structure as described above.

[0124] Further, in the protruding portion of the lightweight structural member 100 according to the present invention, even if the edges of the vertical structure (vertical reinforcing portion) serving as the web function of the plate reinforcing material and the edges of the horizontal structure (horizontal reinforcing portion) serving as the flange function are not finished with metal, the sectional moment of the structure is almost the same, so it does not have a great impact on the overall structural performance. In other words, in terms of optimizing the structural performance, there is no significant difference whether the edges of the protruding portion are finished with metal or the non-foaming polymer that is the core is exposed as it is without finishing. Therefore, considering whether there is a connection between the modules of the lightweight structural members 100 adjacent to each other or other special purposes, the suitability of the above-described side end or lower end finishing structure can be determined.

[0125] In addition to the function of assisting the connection and coupling between two or more lightweight structural members 100, the finishing structure of the lightweight structural member 100 according to the present invention described above can also have additional functions such as sealing the space between the upper plate 110 and the reinforcing plate 120 during the manufacturing process of the lightweight structural member 100.

[0126] Also, the aforementioned finishing members (151 / 152 / 153 / 154 / 155) can be inserted between the upper plate 110 and the reinforcing plate 120, and the contacting surfaces can be adhered by an adhesive. The surfaces contacting the core layer 140 can also be adhered by the adhesive force of the non-foaming polymer itself forming the core layer 140. Even when the finishing material (151 / 152 / 153 / 154 / 155) is made of metal, sufficient strength can be obtained only by inserting and adhering it without the need to forcibly weld it. However, 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 reinforcing plate 120 and the finishing member (151 / 152 / 153 / 154 / 155) in the same manner as described above.

[0127] The lightweight structural material 100 according to the present invention has an upper plate 110 and a reinforcing plate 120 formed very thinly, so that thermal distortion can be minimized by applying laser welding. In particular, after filling with a non-foaming polymer and forming a core layer 140 by curing, laser welding can be performed after providing structural strength, so that welding distortion can be minimized.

[0128] Also, in the lightweight structural material 100 according to the present invention, since the reinforcing plate 120 made of a metal material constituting the protruding portion adheres to the internal core layers 140 with an adhesive strength of 1 MPa or more, more preferably 6 MPa or more, an integrated plate reinforcement function can be realized without separate welding or with only minimal tag welding.

[0129] III. Manufacturing method of lightweight structural material

[0130] Next, with reference to FIGS. 12 to 16, a specific manufacturing method of the lightweight structural material 100 according to the present invention will be described.

[0131] Generally, the thickness of the plate reinforcement used in ships varies from 6 to 30 mm, but usually, a thin thickness of around 6 to 15 mm is used. When replacing this with the structure of the non-foaming polymer and metal composite material proposed in the present invention, the upper plate 110 and the reinforcing plate 120 can use metal thin plates with a thickness of the 1 to 3 mm level, and the thickness of the non-foaming polymer constituting the core layer 140 can be formed in a very thin structure of about 5 to 15 mm.

[0132] By the way, it is not actually easy to form a thin-walled non-foamed polymer structure as described above. This is because the stock solution of the non-foamed polymer has a viscosity higher than that of lubricating oil before being cured. Therefore, if the space to be filled is too narrow, injection becomes difficult due to frictional resistance, and it is difficult to spread evenly within the space. Considering the manufacturing characteristics of the composite material composed of metal and non-foamed polymer and specifying the basic performance and structural requirements of the ship, according to a certain ship classification regulation, the thickness of the metal plate should be at least 3 mm or more, and the core composed of non-foamed polymer should be formed with a thickness of 15 mm or more. If this is not followed, separate approval must be obtained.

[0133] The manufacturing method described below relates to the case where the core layer 140 of the lightweight 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 manufacturing difficulty, that is, the problem that it is difficult to form the core layer 140 composed of non-foamed polymer into a thin wall. More preferably, even when the core layer 140 is formed with a thickness of 15 mm or less, a method is presented that enables the non-foamed polymer to be filled evenly in the space and a uniform core layer 140 to be obtained.

[0134] (1) The first manufacturing method

[0135] Referring to FIG. 12, the first manufacturing method of the lightweight structural material 100 according to the present invention is a method of pouring and filling the non-foamed polymer stock solution on the reinforcing plate 120 and covering it with the upper plate 110. When the lower end of the reinforcing plate 120 is open, it can be formed into a structure with the lower end sealed using seaming, and seaming can also be applied to the side surface of the reinforcing plate 120 so that the space on the reinforcing plate 120 is filled with the non-foamed polymer stock solution to a predetermined water level. If the lower end of the reinforcing plate 120 is formed with a closed structure or finished with a separate finishing member, it may not be necessary to apply seaming, and the same applies to other manufacturing methods described later.

[0136] On the one hand, this manufacturing method does not inject the non-foaming polymer stock solution into a sealed space, but rather pours and fills it into a released space. By proceeding with the operation in the open cavity method, bubbles can be formed by the contact between the non-foaming polymer stock solution and air. If the bubbles are not removed and remain inside the core layer 140, it may affect the structural performance, so an additional process for removing the bubbles is required.

[0137] For this reason, in this manufacturing method, an amount of non-foaming polymer stock solution that is at least 2% more than the volume actually occupied by the core layer 140 is filled on the reinforcing plate 120. When covering the upper plate 110, instead of covering the entire plate at once, a slight inclination or bending is imparted, and the surface of the non-foaming polymer stock solution is covered while pressing it. That is, using the upper plate 110 to cover the surface of the non-foaming polymer stock solution while pressing it from one side to the other side, the excess of the non-foaming polymer stock solution can be extruded out of the panel, and bubbles can be removed through this process. If the lower end of the reinforcing plate 120 is formed in a closed structure, separate holes can also be formed for the overflow and vent of the non-foaming polymer stock solution.

[0138] (2) Second manufacturing method

[0139] The progress of the second manufacturing method of the lightweight structural material 100 according to the present invention will be described with reference to FIG. 13.

[0140] First, with the upper plate 110 inverted, seaming is provided at the edge of the upper plate 110, and a liquid non-foaming polymer stock solution is poured into the space formed by the upper plate 110 and the frame part (seaming). Similarly in this embodiment, an amount of non-foaming polymer stock solution that is at least 2% more than the volume actually occupied by the core layer 140 can be initially filled.

[0141] Then, with the non-foaming polymer stock solution poured into the space of the upper plate 110, the reinforcing plate 120 is inserted from above and pressed downward. The reinforcing 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 between the upper plate 110 and the reinforcing plate 120, a spacer can be arranged between the upper plate 110 and the reinforcing plate 120.

[0142] The non-foaming polymer stock solution filled in the space of the upper plate 110 can melt into the vertical space (a thin gap serving as the web of the plate reinforcement) formed between the leg portions of the reinforcing plate 120 facing each other by the force pressing the reinforcing plate 120. At this time, since the non-foaming polymer stock solution is filled in an amount more than the volume actually occupying the core layer 140, the excess amount can be extruded and discharged outward, and bubbles can also be removed through this process.

[0143] The non-foaming polymer stock solution evenly filled between the upper plate 110 and the reinforcing plate 120 is cured as time passes, the core layer 140 is formed, and the production of the lightweight structural material 100 according to the present invention is completed by the formation of the core layer 140.

[0144] The above-described first and second manufacturing methods are not of the method of injecting the non-foaming polymer stock solution into a sealed space, but of the method of pouring and filling it into a liberated space. These methods can form a thin plate reinforcement structure by overcoming the frictional resistance generated during the injection of the non-foaming polymer stock solution by pressurization, and also have the advantage that the operation can be performed while visually confirming whether the non-foaming polymer stock solution is normally filled in the entire structure corresponding to the core layer 140.

[0145] (3) The third manufacturing method

[0146] Referring to FIG. 14, in the third manufacturing method of the lightweight 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 reinforcing plate 120, and a non-foaming polymer stock solution is injected into the sealed space. However, instead of using only one injection tube for injecting the non-foaming polymer stock solution, it is configured by dividing it into several small tubes.

[0147] Normally, for a non-foaming polymer, a chemical reaction occurs while two kinds of liquids of organic compounds such as ISO and polyol are mixed, 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.

[0148] This manufacturing method is for solving the above-mentioned process difficulties. By dividing the injection tube for injecting the non-foaming polymer stock solution into several small tubes and arranging them secretly in the space where the core layer 140 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 reinforcing plate 120.

[0149] When applying this manufacturing method, if there is a part that is not blocked between the plates, a sealed space can be formed using seaming. If it is finished with a separate finishing member, the finishing member can serve to seal the part. This can be similarly applied to other manufacturing methods.

[0150] (4) Fourth manufacturing method

[0151] Referring to FIG. 15, in the fourth manufacturing method of the lightweight 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 reinforcing plate 120, and a non-foaming polymer stock solution is injected into the sealed space. However, it is a method in which injection is carried out while evacuating the air in the sealed space using a vacuum pump (VP).

[0152] More specifically, after forming a sealed space between the upper plate 110 and the reinforcing plate 120, an injection tube is inserted into one side, and while injecting the non-foaming polymer stock solution, on the opposite side, air inside the sealed space is inhaled using a vacuum pump (VP).

[0153] According to this 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 can it be injected 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).

[0154] (5) Fifth manufacturing method

[0155] The upper plate 110 and the reinforcing plate 120 used in manufacturing the lightweight structural material 100 according to the present invention use metal plates that are much thinner than the iron plates generally used for ships. Therefore, although there are some construction-related nuisances, precisely because the thickness of the metal plate is too thin, it is difficult to maintain the shape of the plate and manage flatness before and during the process of filling the core (non-foaming polymer).

[0156] Conventionally, in the process of filling the core between two plates, spacers have been used to maintain the shape (or maintain the interval). Also, when using a non-foaming 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 reinforcing 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 above-described conventional method.

[0157] In addition, the phenomenon of the plate deflecting due to the self-weight of the upper plate also occurs. At this time, when the thickness of the core is formed thick enough, since the intensity of the chemical reaction is also strong, it is possible to push up the deflected upper plate again by utilizing the swelling force. However, when the core layer 140 is formed thin as in the present invention, since the swelling force is weak, it is not possible to restore the deflection of the upper plate 110 due to the self-weight.

[0158] Moreover, the lightweight structural material 100 according to the present invention includes a structure in which the reinforcing plate 120 is bent downward. In this case, due to the characteristic that the reinforcing plate 120 is composed of a thin sheet, it is also very difficult to maintain a constant bending angle.

[0159] The fifth manufacturing method of the lightweight structural material 100 according to the present invention is proposed to solve the above-mentioned difficulties in the manufacturing method. If the above-mentioned first to fourth manufacturing methods are methods related to the filling of non-foaming polymers, the fifth manufacturing method can be regarded as a method for maintaining the shape and flatness of the entire structural material before and during the injection of the non-foaming polymer.

[0160] Specifically, as shown in FIG. 16, when a magnet (M) is disposed on the upper surface of the upper plate 110 disposed above in a state where the space between the upper plate 110 and the reinforcing plate 120 is filled with the non-foaming polymer stock solution, the upper surface of the upper plate 110 comes into close contact with the magnet (M) due to the magnetic field generated by the magnet (M), and can maintain a flat state.

[0161] For reference, in the embodiment shown in FIG. 16, since the process proceeds with the reinforcing plate 120 and the upper plate 110 sequentially stacked on the surface plate, the magnet (M) is disposed on the upper surface of the upper plate 110. If the process proceeds with the upper plate 110 and the reinforcing plate 120 reversed, the magnet (M) can be disposed on the upper surface of the reinforcing plate 120 placed on the upper side with respect to the non-foaming polymer stock solution.

[0162] Here, the magnet (M) can be understood as a concept including an electromagnet and all magnetic bodies capable of generating a force to attract metal. The magnet (M) does not necessarily need to be configured with 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 achieved. Also, a plurality of magnets (M) can be arranged on the plate. When only one magnet (M) is used, it is preferably arranged at the central part of the plate.

[0163] Moreover, not only can it be placed horizontally, but magnets (M) can also be arranged on the side surface of the reinforcing plate 120 erected vertically in the same principle to maintain flatness and obtain a desired bending angle.

[0164] At this time, the magnet (M) can be configured to be included in a working jig or a surface plate for fixing the positions of the upper plate 110 and the reinforcing plate 120. Although the drawing shows that only the magnet (M) applying a tensile force to the reinforcing plate 120 is included in the surface plate, it is natural that the magnet (M) applying a tensile force to the upper plate 110 can also be included in the working jig or the surface plate. In this case, even without providing a separate gripping part for fixing the upper plate 110 or the reinforcing plate 120 to the working jig or the surface plate, the incidental effect that the upper plate 110 or the reinforcing plate 120 made of a metal plate can be easily gripped by the force exerted by the magnet can also be enjoyed.

[0165] Also, this manufacturing method can also be implemented by using a vacuum adsorption device instead of the magnet (M). Specifically, by adsorbing a specific part of the plate whose flatness is to be maintained with the vacuum adsorption device and applying a tensile force, the form of the structural material can be maintained and the flatness can be maintained.

[0166] Similar to the case of applying the magnet (M), the vacuum adsorption device can also execute the flatness maintenance function by providing an adsorption force only for a partial area rather than the entire area of the plate. Preferably, it is good to adsorb the central part of the plate whose flatness is to be maintained. Also, it is possible to apply a plurality of vacuum adsorption devices on one plate.

[0167] The lightweight structural material 100 according to the present invention, which is manufactured by applying the fifth manufacturing method as described above, has a flat surface and can maintain the same thickness throughout, so that uniform structural performance can be realized. In addition, by solving the flatness problem in the manufacturing process, the amount of the spacer disposed between the upper plate 110 and the reinforcing plate 120 is greatly reduced, and there is also an effect that the manufacturing man-hours and costs can be saved.

[0168] According to the thickness and edge treatment method for forming the structure of the lightweight structural material 100 according to the present invention, two or more of the above-described first to fifth manufacturing methods can be applied in parallel. For example, while performing the second 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 fourth manufacturing method. Also, while injecting the non-foaming polymer stock solution using several injection tubes as in the third manufacturing method, it is also possible to apply the vacuum pump of the fourth manufacturing method together. In the case of the fifth manufacturing method, since it is a method applied to maintain the form and flatness of the structural material, it can be said that it can be applied in parallel with any other manufacturing method.

[0169] In addition, since the thin non-foaming polymer has a smaller absolute volume in which a chemical reaction occurs than the thick non-foaming polymer, more time is required for curing. In particular, in a period with a low temperature such as winter, since the rate of the chemical reaction between molecules for curing also decreases, the curing time takes longer, or extremely, it may not be cured. To prevent this, the surface of the manufacturing jig can be provided with a heat ray or a warm water piping facility whose temperature can be raised, and this is a case that can be commonly applied to all manufacturing methods.

[0170] IV. Additional Embodiments of the Lightweight Structural Material

[0171] On the one hand, when constructing the core layer 140 of the lightweight 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 have already been realized. In this case, by additionally arranging a high-performance heat insulating material with a low thermal conductivity between the upper plate 110 and the reinforcing plate 120, it becomes possible to have excellent performance on the heat insulating side surface.

[0172] More specifically, as shown in FIG. 17, the core layer 140 can be formed by arranging a high-performance heat insulating material 141 having a thermal conductivity lower than 0.02 W / mK together with a non-foaming polymer between the upper plate 110 and the reinforcing plate 120. As an example, when forming the core layer 140 to include a vacuum insulating panel (VIP) having a thermal conductivity at the level of 0.004 W / mK, the total thickness of the lightweight structural material 100 is assumed to increase to 20 to 40 mm. However, in terms of heat insulation performance, it is possible to realize heat insulation performance that is about 6 to 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 realized while being lightweight.

[0173] 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, and the gas entry and exit to the vacuum insulating material is perfectly blocked by the closed structure of the non-foaming polymer, achieving the effect of almost doubling the lifespan of the vacuum insulating material.

[0174] When the core layer 140 is composed only of a non-foamed polymer, there is an advantage that the thickness of the lightweight structural material 100 can be optimized to be very thin. When additionally including a high-performance heat insulating material 141 such as a vacuum heat insulating material together with the non-foamed polymer, in terms of manufacturing the lightweight structural material 100, there is an advantage that it is more convenient (because the non-foamed polymer stock solution can be applied to the surface of the high-performance heat insulating material 141 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 140 of the lightweight structural material 100 according to the present invention, it is possible to select and apply whether to use the non-foamed polymer alone or to use the high-performance heat insulating material 141 in parallel.

[0175] For reference, when the core layer 140 is composed only of the high-performance heat insulating material 141, the bonding strength with the upper plate 110 and the reinforcing 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 141 maintains a form firmly fixed by adhesion between the upper plate 110 and the reinforcing plate 120, can the lightweight structural material 100 of the present invention obtain satisfactory structural performance.

[0176] V. Application Examples of the Lightweight Structural Material

[0177] The lightweight structural material 100 according to the present invention can be utilized to form a ship structure or the floor, ceiling, and wall structures of a building. Preferably, the lightweight structural material 100 according to the present invention can be used as a deck structure of a ship. Also, the lightweight structural material 100 according to the present invention can be provided above or below a concrete slab that divides the upper and lower floors in a building and used as a floor or ceiling structure, and it goes without saying that it can also be applied to the wall structure of a building as needed. Hereinafter, specific application examples of the lightweight structural material 100 according to the present invention and the effects thereof will be described.

[0178] (1) Ship Structure

[0179] The lightweight structural material 100 according to the present invention is applicable to forming the deck of a ship or the floor structure of a ship deckhouse. In particular, when the lightweight structural material 100 according to the present invention is applied to the production of the car deck of a pure car carrier (PCC) in the shipbuilding industry, it is expected to have extremely excellent usability and is also effective in forming the floor structure of a ship deckhouse.

[0180] When the lightweight structural material 100 according to the present invention is utilized as a ship structural material, it is possible to achieve the effect of solving the problem of conventional welding thermal distortion.

[0181] Conventionally, in order to construct the deck of a ship, a general steel plate structural material in the form shown in FIG. 1 has been mainly used. In this case, as described above, it has been impossible to avoid the problem of serious thermal distortion occurring due to welding a plate reinforcement 20 under the upper plate 10 that serves as a structural member. Also, considering only the structural performance as a normal ship deck, the upper plate 10 of the steel plate structural material may be formed with a thickness of only about 6 mm. However, considering the thermal distortion caused by welding the plate reinforcement 20, the thickness of the upper plate 10 is frequently increased by about 10 mm from the beginning during production. However, even if the thickness of the upper plate 10 is increased, the problem of thermal distortion due to welding the plate reinforcement 20 still always exists. Therefore, in reality, a considerable amount of man-hours are invested in correction work through hot working after welding most of the plate reinforcements 20.

[0182] However, the lightweight structural material 100 according to the present invention is in a form in which a protrusion that functions as a plate reinforcement is already included in the structure and does not require welding for attaching the plate reinforcement. Therefore, the amount of welding required for the entire process and the resulting thermal distortion can be significantly reduced. Thus, the problem of thermal distortion caused by welding of the steel plate structural material that has been mainly used in the shipbuilding industry can be fundamentally solved.

[0183] In addition, when connecting lightweight structural members 100 adjacent to each other, in the present invention, finishing materials made of metal materials are welded to each other, or lightweight structural members 100 that already have rigidity ensured by the core layer 140 formed inside are welded to each other, so that the amount of thermal distortion of the entire plate can be greatly reduced.

[0184] In addition, the lightweight structural member 100 according to the present invention composed of a composite material can achieve equivalent structural performance with a weight that is about 40 to 50% lighter than that of a conventional iron plate, so it can greatly contribute to the weight reduction of ships.

[0185] (2) Building Structure

[0186] In the lightweight structural member 100 according to the present invention, since the space between the upper plate 110 and the reinforcing plate 120 is almost filled with a non-foaming polymer, it has a thermal conductivity of 0.2 to 0.4 W / mK, which is similar to that of high-density wood. This has an insulating performance that is incomparably excellent compared to a general iron plate structural material (k = 83 W / mK) mainly used for ships, and it also means that it has better insulating performance compared to reinforced concrete (k = 1.6 W / mK) used for construction. In addition, the lightweight structural member 100 according to the present invention, which has excellent performance in terms of vibration / noise reduction as a role of the elastic non-foaming polymer, can be sufficiently used not only as a ship structural material but also as an onshore floor or wall structure.

[0187] Typically, both ends along the longitudinal direction of the lightweight structural member 100 according to the present invention can be structurally connected to a wall to form the floor or ceiling structure of a building. Hereinafter, embodiments of using the lightweight structural member 100 according to the present invention as a building floor structure and ceiling structure will be sequentially described.

[0188] A. Building Floor Structure (Double Floor)

[0189] The lightweight structural member 100 according to the present invention can be used for the floor structure of a building. In particular, since it can be manufactured as a long-span structure, it can be very usefully utilized to form a double-floor structure of a building.

[0190] Referring to FIG. 18, the lightweight structural member 100 according to the present invention can have both longitudinal edges fixed to the wall of the upper floor building. At this time, it is arranged with a slight gap above the concrete slab that constitutes the upper floor, and a double floor structure can be realized.

[0191] 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. That is, a general multi-story building has a structure where the floor structure of the upper floor forms the ceiling structure of the lower floor, and one concrete slab is shared by two floors. Therefore, it is fundamentally vulnerable to noise transmission through this.

[0192] As a method for solving such inter-floor noise problems, a double floor structure is most widely used. However, a generally known conventional double floor structure is a structure in which an additional lightweight floor is installed on the concrete slab. That is, it forms two floors and provides an air layer between them to block sound transmission.

[0193] However, in such a 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 about several tens to several hundreds of support bases for supporting between the lightweight floor and the concrete slab. Therefore, the transmission of noise / vibration through a large number of support bases cannot be ignored. There are also problems such as an increase in installation man-hours and costs due to the requirement of installing a large number of support bases.

[0194] However, since the lightweight structural member 100 according to the present invention can be manufactured as a long-span structure, sufficient structural performance can be ensured only by fixing both longitudinal edges along the longitudinal direction to the wall of the building. Therefore, it is possible to realize a solid and perfect double floor structure without a separate lower support structure.

[0195] That is, when forming the upper floor with the lightweight structural member 100 according to the present invention to implement a double floor structure, there is no need to provide a separate support base for supporting the lightweight structural member 100 on the concrete slab. Therefore, the upper floor and the concrete slab are structurally completely separated, and it becomes possible to implement a double floor structure that is very effective in reducing inter-story noise.

[0196] Next, referring to FIG. 18, the effect of reducing inter-story noise by applying the lightweight structural member 100 according to the present invention will be described more specifically.

[0197] Generally, inter-story noise can be classified into two types: primarily, the weight or frictional impact sound generated on the upper floor is transmitted through the floor structure, and secondarily, it is transmitted from the upper floor through the wall. However, in the double floor structure implemented using the lightweight structural member 100 according to the present invention, the impact sound generated on the side of the lightweight structural member 100 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 sound is transmitted by the energy of sound rather than directly by vibration, the total amount of energy transmitted to the lower floor can be greatly reduced.

[0198] Also, the vibration transmitted from the lightweight structural member 100 that constitutes the upper floor on the upper floor through the wall is not immediately 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 is greatly reduced.

[0199] Moreover, the present invention proposes several buffer structures that can mitigate impacts when connecting the lightweight structural member 100 and the wall so as to more effectively block the transmission of noise through the wall from the lightweight structural member 100, thereby maximizing the effect of reducing inter-story noise.

[0200] Hereinafter, referring to FIGS. 19 to 22, the connection structure applicable between the lightweight structural member 100 and the wall according to the present invention will be examined.

[0201] First, referring to FIG. 19, the first wall connection structure will be described. In the first wall connection structure, an anchor pad 211 is installed 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 lightweight structural member 100. The anchor pad 211 and the metal plate 212 are fixed and connected to each other through bolt fastening. At this time, a vibration reduction buffer material can be arranged between the anchor pad 211 and the metal plate 212 so as to relieve the impact transmitted from the lightweight structural member 100 to the wall.

[0202] Next, referring to FIG. 20, the second wall connection structure will be described. In the second wall connection structure, the lower part of the anchor pad 221 installed on the building wall is provided in an L-shaped angle form (or an L-shaped angle member is coupled to the lower end of the anchor pad 221), and the lower end part 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.

[0203] The upper end part of the metal plate 222 can be fixed to the anchor pad 221 or the wall through bolt fastening.

[0204] And for the purpose of relieving the impact transmitted from the lightweight structural member 100 to the wall, a vibration reduction buffer material or a spring can be additionally arranged between the metal plate 222 and the anchor pad 221.

[0205] The second wall connection structure is a method in which the lower end part of the metal plate 222 is simply inserted into the space without mechanical fastening by a separate member and is accommodated and supported, and only the upper end part is fastened by bolt fastening. By placing the metal plate 222 on the anchor pad 221 including the L-shaped angle and fixing only the upper end part to the wall side, the workability at the site is very simple and a structurally firm connection is possible.

[0206] Next, referring to FIG. 21, the third wall connection structure will be described. In the third wall connection structure, an anchor pad 231 installed on the wall of the building and a metal plate 232 welded and fixed to the edge along the longitudinal direction of the lightweight structural member 100 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 disposed between the anchor pad 231 and the metal plate 232, which can mitigate the impact transmitted from the lightweight structural member 100 to the wall.

[0207] In the third wall connection structure, it is also possible to dispose a vibration reduction buffer material between the anchor pad 231 and the metal plate 232 instead of the spring 233, or to dispose the vibration reduction buffer material together with the spring 233.

[0208] If the second wall connection structure shown in FIG. 20 is a structure that allows some movement within a predetermined range without restricting the lower end of the metal plate 222, the third wall connection structure shown in FIG. 21 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.

[0209] Finally, the fourth wall connection structure shown in FIG. 22 is a method of connecting the lightweight structural member 100 to the wall of the building through a vibration reduction device 241 without directly connecting them. Here, the vibration reduction device 241 may be a hydraulic device or a spring device that can absorb vibrations in the vertical direction.

[0210] When applying the fourth wall connection structure, the vibration caused by the impact generated in the lightweight structural member 100 is not transmitted to the wall. In addition, the vibration transmitted from the lightweight structural member 100 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 mitigated.

[0211] In addition, although not shown in the drawings, in addition to the above-described first to fourth wall connection structures, various cushioning materials are arranged in the space between the lightweight structural material 100 and the concrete slab, and by realizing an additional damping effect, it is also possible to reduce additional inter-story noise.

[0212] B. Ceiling Structure of Building

[0213] Although not shown separately, it is also possible to provide the lightweight structural material 100 according to the present invention under the concrete slab and utilize it as the ceiling structure of the lower floor.

[0214] In this case, since the ceiling finishing material of the lower floor can be directly attached to the lower surface of the lightweight structural material 100, separate support base construction and carpentry work for attaching the ceiling finishing material are not required, and the effect of simplifying the ceiling construction can be achieved.

[0215] In addition, since various pipes and concealed pipes to be constructed on the ceiling (for example, ceiling-embedded type air conditioners) can be easily attached to the lightweight structural material 100 according to the present invention, the application of the modular construction method is also possible via pre-piping.

[0216] C. Utilization as a Superimposed Structure

[0217] As shown in FIG. 23, it is also possible to stack and utilize the lightweight structural materials 100 according to the present invention vertically.

[0218] When the lightweight structural materials 100 are arranged in two layers in this way, various concealed pipes are pre-constructed in the space where the upper / lower lightweight structural materials 100 face each other, so that various additional functions can be easily added.

[0219] As an example, referring to FIG. 24, a heat insulating material (I) and a heating / cooling pipe (P) can be installed in the space between the lightweight structural members 100 that are superposed vertically, and the ondol function can be easily added. Here, the heat insulating material (I) can be arranged only below the heating / cooling pipe (P) so that the cold or warm heat from the heat fluid flowing through the heating / cooling pipe (P) can be well transmitted upward, and the periphery of the heating / cooling pipe (P) can be provided as an empty space.

[0220] Normally, for the floor mortar finishing work for ondol, a process is required in which a heat insulating material is laid on a concrete slab, a hot water pipe is provided thereon, and then a finishing mortar is applied thereon. Here, when applying the mortar, in order to obtain a uniform flatness, a mortar containing a large amount of moisture must be used, so it takes a long time to harden and there are many nuisances in the work.

[0221] However, when applying the present invention, since the lightweight structural member 100 arranged on the upper part performs a structural function, separate mortar application is not required, so it is very convenient and the ondol structure and / or the floor heating / cooling structure can be constructed simply.

[0222] In addition to this, referring to FIG. 25, by adding a refractory material (R) between the lightweight structural member 100 arranged at the lower part and the heat insulating material (I), it is possible to realize the fire resistance performance of the floor without separate fire protection coating.

[0223] According to the domestic and foreign floor fire resistance standards, whether the temperature of the non-heated surface of the structural member rises is also important, but at the same time, the structural stability against the occurrence of a fire is being considered and emphasized. More specifically, with a weight body of a certain load or more (for example, 3 kN / m 2 ) placed on the upper part of the structural member, the lower part of the structural member is exposed to a heat source, and after a certain time (for example, 2 hours) has elapsed, the amount of deflection of the structure is confirmed to evaluate the structural stability.

[0224] In the case of conventional building structural materials typically made of metal, when exposed to heat during a fire resistance test, once the temperature reaches a certain level, they lose their structural performance. Therefore, in order to meet the fire resistance standards, additional subsequent work of coating the metal part with fire-resistant materials is carried out.

[0225] However, as shown in FIG. 25, when a fire-resistant material (R) is disposed in advance inside the superimposed structure formed by the superimposed arrangement of the lightweight structural materials 100, the lightweight structural materials 100 disposed at the lower part are exposed to the heat source due to a fire. Even if they lose their structural performance, the upper lightweight structural materials 100 protected by the fire-resistant material (R) can maintain their structural performance. Therefore, even without performing additional fire-resistant coating work as in the prior art, the structural stability can be maintained in the event of a fire, and the above-mentioned fire resistance standards can be easily met.

[0226] When superimposing the lightweight structural materials 100 according to the present invention, when attempting to impart additional functions to the space therebetween, or when attempting to double the effect of reducing interlayer noise by incorporating a double floor structure into the structure itself, the lightweight structural materials 100 facing each other vertically can be disposed at a predetermined interval. Also, at this time, since each of the lightweight structural materials 100 constituting the superimposed structure can be individually fixed in the structure, it is not necessarily required that the lightweight structural materials 100 disposed vertically be structurally directly connected.

[0227] When the lightweight structural materials 100 according to the present invention are superimposed in a double layer and used as the floor structure of a building, the impact sound that is the direct cause of interlayer noise is generated by the lightweight structural materials 100 disposed on the upper side. Therefore, the upper lightweight structural materials 100 apply the above-described first to fourth wall connection structures and are connected to the wall of the building so as to be able to buffer, and the lightweight structural materials 100 disposed on the lower side can be connected to the wall through simple mechanical fastening such as bolt tightening.

[0228] When the lightweight structural materials 100 according to the present invention are utilized as the structural materials of a building, the following effects can be expected.

[0229] First, it is possible to realize an ultra-light long-span dry structure with far superior structural performance, and when using this, the efficiency of all construction work can be greatly increased.

[0230] During construction, reinforced concrete floor construction is a basic structural work that is the most complicated and occupies many construction periods among all construction work. In particular, it is greatly affected by the environment and is manufactured by a wet construction method with poor site conditions, so it is also cited as one of the most important construction work in terms of construction management and performance realization. Recently, in order to shorten the construction period, pushing forward the wet concrete slab construction forcefully has also led to major accidents.

[0231] The lightweight structural material 100 presented in the present invention weighs only about 30 to 40% of that of ordinary concrete, 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 construction method, it is hardly affected by the environment, and thus has the advantage of significantly reducing complicated and poor on-site processes. Also, different from the wet construction method, the structural performance is realized immediately after installation, so the entire construction period can be greatly shortened.

[0232] Also, when using the lightweight structural material 100 according to the present invention, it is possible to realize a rigid double-floor structure that does not require a support base, and thus the problem of inter-floor noise, which has become a major social issue, can be very significantly reduced.

[0233] Also, when using the lightweight structural material 100 according to the present invention as the floor structure of a building, the ondol floor mortar finishing work can be simplified. As seen before, since the lightweight structural material 100 according to the present invention has far superior structural performance, there is no need to perform ondol work (heating work) on the lightweight floor in order to increase the structural strength as in the conventional double-floor structure. Therefore, when installing the lightweight structural material 100 according to the present invention on a conventional concrete slab, the hot water piping and heating and cooling piping work 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 separate mortar work for floor mortar finishing.

[0234] 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, floor mortar work had to be carried out or a separate dry-type ondol panel had to be additionally installed before the finishing floor material could be constructed. However, since the lightweight structural material 100 according to the present invention itself functions as a sufficient structural material, the conventional separate floor mortar work or dry-type ondol panel installation work is no longer necessary, and since the finishing floor material can be immediately constructed on the lightweight structural material 100, the floor mortar finishing work for ondol can be greatly simplified.

[0235] Step construction can also be simplified. Usually, toilet and entrance floors are designed to have a step about several tens of millimeters (mm) lower than other floor slabs. As a conventional construction method, formwork work, floor mortar finishing work, etc. were required to form such a step. However, according to the present invention, since all floor slabs on the same floor can be manufactured flat and only the lightweight structural material 100 needs to be stepped, the step construction is simplified, and there is an advantage that it is very convenient to manufacture the step structure for toilet and entrance floor slabs.

[0236] Also, when the lightweight structural material 100 according to the present invention is used as the ceiling structure of a building, since the ceiling finishing material of the lower floor can be directly attached to the lower surface of the lightweight structural material 100, the ceiling construction can be simplified, and the application of the modular construction method is also possible through the pre-installed pipes for various pipes and concealed pipes to be constructed on the ceiling in the lightweight structural material 100.

[0237] Also, when the lightweight structural material 100 according to the present invention is stacked vertically and utilized as a stacked structure, there is an advantage that pre-construction of various pipes, ceiling fixtures, etc. can be carried out inside or below the structure.

[0238] For example, by easily mounting the heat insulating material (I) required for the floor ondol, the pipes (P) for heating and cooling, etc. as preliminary piping into the structure (refer to Fig. 24), the separate floor mortar finishing work for the ondol can be omitted, and thus, the overall building process can be greatly simplified. Also, the reaction of the floor temperature to temperature adjustment can be made faster, and the structure for raising the temperature is much lighter and simpler, so it is also much more advantageous in terms of thermal efficiency. Additionally, when a refractory material (R) is additionally arranged in the structure as preliminary piping (refer to Fig. 25), there is an advantage that the fire resistance performance itself can be sufficiently realized without separate subsequent fireproofing work.

[0239] The present invention is not limited to the described embodiments, and it is obvious to those having 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. An upper plate made of a flat metal material, a plurality of reinforcing plates made of a metal material, including a horizontal plate formed in the horizontal direction and a vertical plate bent downward from the horizontal plate, and arranged at a predetermined interval below the upper plate, and a core layer made of a non-metal material formed in the space between the upper plate and the reinforcing plate and in the space between the adjacent reinforcing plates, the plurality of formed vertical plates form a pair of those facing each other closely, and a pair of vertical plates and a core layer formed therebetween constitute a protrusion that functions as a plate reinforcing material, the protrusion is formed at regular intervals along the horizontal direction and extends while maintaining a constant cross-sectional shape along the longitudinal direction, and is characterized in that a composite material-based plate reinforcing material integrated lightweight structural material.

2. The core layer is characterized in that it is formed of a non-foaming polymer, The composite material-based plate reinforcing material integrated lightweight structural material according to Claim 1.

3. The horizontal plate and the vertical plate constituting the reinforcing plate are characterized in that they are formed by bending a single plate material, The composite material-based plate reinforcing material integrated lightweight structural material according to Claim 1.

4. The lower end of the protrusion is bent again, or a separate metal finishing material is joined to the lower end of the protrusion, and the lower end of the protrusion has an "L"-shaped cross-section or a "⊥"-shaped cross-section, a vertical reinforcing portion formed vertically from the protrusion performs the web function of the plate reinforcing material, and a vertical reinforcing portion formed horizontally from the protrusion performs the flange function of the plate reinforcing material, and is characterized in that The composite material-based plate reinforcing material integrated lightweight structural material according to Claim 1.

5. Among the plurality of reinforcing plates, the remaining reinforcing plates except for the reinforcing plates arranged at least at both edge ends along the width direction have a "C"-shaped cross-section, further including a lower plate arranged at a predetermined interval below the reinforcing plate, the core layer is further formed additionally between the reinforcing plate and the lower plate, manufactured to include a ladder shape as a whole, The composite material-based plate reinforcing material integrated lightweight structural material according to Claim 1.

6. Characterized in that a high-performance heat insulating material with a thermal conductivity of 0.02 W / mK or less is additionally arranged in the core layer, The composite material-based plate reinforcing material integrated lightweight structural material according to Claim 2.

7. The high-performance heat insulating material is characterized in that it is a vacuum insulating panel (VIP: Vacuum Insulation Panel), The composite material-based plate reinforcement integrated lightweight structural material according to claim 3.

8. Further comprising side end finishing materials for finishing both edge ends of the upper plate and the reinforcing plate, The side end finishing material is inserted between the upper plate and the reinforcing plate, but is pushed in by a predetermined distance from the edge ends of the upper plate and the reinforcing plate, and is characterized in that, The composite material-based plate reinforcement integrated lightweight structural material according to claim 1.

9. When connecting the lightweight structural materials adjacent to each other, the upper plates facing each other and the lower plates facing each other are joined by welding, and a non-foaming polymer stock solution is injected into the space formed between the upper plate, the lower plate, and the side end finishing material, and the connecting part is finished airtight by curing, and is characterized in that, The composite material-based plate reinforcement integrated lightweight structural material according to claim 8.

10. Further comprising side end finishing materials for finishing both edge ends of the upper plate and the reinforcing plate, The side end finishing material is provided in an angle form having a cross section of a single character shape or a "¬" character shape, one end is inserted between the upper plate and the reinforcing plate, and the other end protrudes outside the upper plate and the reinforcing plate, and is characterized in that, The composite material-based plate reinforcement integrated lightweight structural material according to claim 1.

11. When connecting the lightweight structural materials adjacent to each other, the side end finishing materials facing each other are structurally joined by welding or bolting, and is characterized in that, The composite material-based plate reinforcement integrated lightweight structural material according to claim 10.

12. A ship deck structure manufactured using the lightweight structural material according to any one of claims 1 to 11.

13. The ship is an automobile carrier (PCC: Pure Car Carrier), and the ship deck structure according to claim 12 is characterized in that.

14. In a method of manufacturing a lightweight structural material including an upper plate made of a flat metal material, a plurality of reinforcing plates made of metal material including a horizontal plate formed horizontally and a vertical plate bent downward from the horizontal plate, which are arranged at a predetermined interval below the upper plate, and a core layer formed in the space between the upper plate and the reinforcing plate and in the space between adjacent reinforcing plates, Filling the space between the upper plate and the reinforcing plate and the space between adjacent reinforcing plates with a non-foaming polymer stock solution, Curing the non-foaming polymer stock solution, and including the stage where the non-foaming polymer stock solution is cured and the formation of the core layer is completed A method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material

15. In the stage of filling the non-foaming polymer stock solution, a space is formed on the upper plate. After pouring the non-foaming polymer stock solution, the reinforcement plate is inverted and put in from above, and pressurized until it reaches a position with a predetermined distance from the upper plate. By this, the non-foaming polymer stock solution melts into the space between the reinforcement plate while overcoming the frictional resistance due to viscosity by the force applied by the reinforcement plate and is filled evenly. It is characterized by this The method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material according to claim 14

16. The amount of the non-foaming polymer stock solution initially poured into the space on the upper plate is poured in an amount at least 2% more than the actual volume occupied by the core layer, and the excess is extruded and discharged outward by the force applied by the reinforcement plate. It is characterized by this The method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material according to claim 15

17. In the stage of filling the non-foaming polymer stock solution, the space where the core layer is formed is sealed, and the non-foaming polymer stock solution is injected into the sealed space using an injection pipe. However, the injection pipe is divided into several small pipes and arranged in the sealed space. It is characterized by this The method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material according to claim 14

18. In the stage of filling the non-foaming polymer stock solution, the space where the core layer is formed is sealed, an injection pipe is inserted into one side of the sealed space, and while injecting the non-foaming polymer stock solution, on the other side, air in the sealed space is inhaled using a vacuum pump. It is characterized by this The method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material according to claim 14

19. In at least one of the stage of filling the non-foaming polymer stock solution and the stage of curing the non-foaming polymer stock solution, for the purpose of maintaining flatness and maintaining an accurate angle, a magnet is arranged on at least one of the upper plate and the reinforcement plate, or adsorbed with a vacuum adsorption device and a tensile force is applied. It is characterized by this The method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material according to claim 14

Images