Lightweight structural material with integrated plate reinforcement based on composite material, ship deck structure manufactured using the same, and method for manufacturing lightweight structural material with integrated plate reinforcement based on composite 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 reinforcement integrated lightweight structural material, a ship deck structure manufactured using the same, and a method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material. More specifically, when the ship is dry, it fundamentally solves the problem of thermal distortion caused by welding the upper plate and the plate reinforcement during the manufacturing process of the mainly used steel plate structural material, significantly 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 reinforcement integrated lightweight structural material, a ship deck structure manufactured using the same, and a method for manufacturing a composite material-based plate reinforcement integrated lightweight structural material.

Background Art

[0002] Generally, the structural materials mainly used in ships are steel plate structural materials made of only metal. As shown in FIG. 1, a conventional ship steel plate structural material is manufactured in a form where a plate reinforcement 20 made of metal is welded to an upper plate 10 made of metal. At this time, the plate reinforcement 20 is composed of a Longitudinal girder 21 for reinforcing the longitudinal structure and a Transverse frame 22 for reinforcing the transverse 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 reinforcement 20 for longitudinal strength reinforcement at intervals of 500 to 900 mm between frames. However, when the plate reinforcement 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 thermal distortion caused by welding. When welding the plate reinforcement 20, the welding area is heated to approximately 1,000 to 1,500°C, and considerable stress and distortion occur as the heated iron plate cools. As a result, after welding the plate reinforcement 20, a bend is inevitably formed across the entire plate with a deviation of several tens of millimeters per meter, and therefore, enormous labor and costs are incurred in the subsequent correction work.

[0006] In particular, when it comes to structural materials used for car decks and deckhouse walls on car carriers (PCCs), thin plates with a top plate thickness of about 6-10 mm are required. However, when structures are formed with such thin walls, problems due to welding distortion occur far more frequently than in other areas, such as the top plate itself cracking due to welding distortion or twisting so severely that it is impossible to correct in subsequent correction processes.

[0007] Currently, to prevent the aforementioned problems from occurring, we simply use top plates that are far thicker than the structurally required thickness, or we invest enormous amounts of labor and expense in correcting thermal distortion in subsequent processes. Therefore, a more fundamental solution is needed.

[0008] On the other hand, laser welding is a welding method known to produce far less thermal distortion than arc welding or gas welding, which are commonly used in the shipbuilding industry. Laser welding is a method of joining materials by concentrating light energy emitted from a laser source onto 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 not by power but by the thermal conductivity of the metal and the vaporization of the metal at the surface. Therefore, when applied to thick base materials, the welding efficiency is significantly reduced.

[0009] While it is generally known that laser welding is possible up to 6 mm thick, in reality, the welding speed of laser welding deteriorates significantly when the thickness exceeds 4 mm. Therefore, laser welding is generally applied mainly when the base material thickness is 3 mm or less. In other words, it is not easy to apply laser welding to 6 mm thick steel plates, which are typically known as the thinnest structure in shipbuilding. Furthermore, a considerable amount of energy is required to melt a 6 mm thick top plate, and even then, a similar welding distortion occurs as the considerably large welded area cools, so there is no significant advantage.

[0010] (2) Weight problem

[0011] Another drawback of conventional steel sheet structural materials for ships is their excessive weight. Of course, the steel sheet structural materials primarily used in ships are far lighter than reinforced concrete used in construction, but "ship weight reduction" has become one of the biggest topics of discussion globally in the shipbuilding and marine sectors, given the increasing importance of environmentally friendly ships, cost reduction, and labor cost savings. Reducing the weight of a ship reduces the energy required for propulsion, thus reducing carbon emissions. Furthermore, ship weight reduction is also extremely important in terms of ensuring the stability of the ship.

[0012] In particular, in the case of car carriers (PCCs) with multiple decks, the weight of the decks themselves shifts the center of gravity of the vessel upwards, which significantly impairs the vessel's stability. Therefore, reducing the weight of the decks and achieving a lighter vessel is of paramount importance.

[0013] (3) Problem of its limited use as a structural material in buildings

[0014] Although the conventional steel plate structural materials mentioned above are far lighter than reinforced concrete and can achieve equivalent structural performance with thin walls, they are not widely used in the construction field. The biggest reason for this is precisely the noise transmission characteristic of steel plates. Because the entire structure of steel plate structural materials is composed of a single, high-density metal, when subjected to impact, they have superior noise transmission capabilities compared to any structural material made from other materials. For this reason, they are rarely used as building materials, especially as flooring materials in buildings where preventing inter-story noise is important.

[0015] Furthermore, steel sheet structural materials are unsuitable as building materials where insulation is crucial, due to their excessively high thermal conductivity. While reinforced concrete has a thermal conductivity of 1.6-2.0 W / mK, steel sheet has a very high thermal conductivity of 83 W / mK. Having high thermal conductivity means that external heat is transferred to the interior very quickly and easily, making it extremely vulnerable in terms of insulation. [Overview of the Initiative] [Problems that the invention aims to solve]

[0016] The objective of the present invention is to overcome the aforementioned technical limitations and provide a lightweight structural material with integrated plate reinforcement based on a high-performance / multifunctional composite material that can be effectively applied to the thin plate structure of ships, as well as to the construction field (particularly the floor structure of buildings).

[0017] More specifically, the present invention aims to provide a lightweight structural material with integrated plate reinforcement based on a composite material, which can eliminate the joining process of the lower plate reinforcement required in conventional shipbuilding steel plate structural materials, thereby solving the problem of thermal distortion caused by welding in conventional shipbuilding steel plate structural materials. Compared to conventional shipbuilding steel plate structural materials and other structural materials, it is extremely lightweight, enabling structural weight reduction, and is applicable to the construction field.

[0018] Furthermore, the present invention aims to provide a lightweight structural material with an integrated plate reinforcement, based on a composite material, that can have a top plate of a thickness similar to that of general shipbuilding steel plate structural materials, and whose form and assembly method are similar to those of general shipbuilding steel plate structural materials, making it easily usable as a ship structure, and particularly usable for the manufacture of deck structures of ships such as car carriers (PCCs).

[0019] The technical problems of the present invention are not limited to those described above, and other technical problems not mentioned can be clearly understood by an ordinary person by the following description. [Means for solving the problem]

[0020] According to one aspect of the present invention for achieving the above objective, a composite material-based plate-reinforced lightweight structural material can be provided, comprising a flat metal top plate, a horizontal plate formed horizontally and a vertical plate bent downward from the horizontal plate, a plurality of metal reinforcing plates arranged at predetermined intervals below the top plate, and a non-metallic core layer formed in the space between the top plate and the reinforcing plates and in the space between adjacent reinforcing plates, wherein the plurality of vertical plates form a pair of plates that are close to each other and facing each other, and the pair of vertical plates and the core layer formed between them constitute a protrusion that functions as a plate reinforcement, the protrusion is formed at regular intervals along the horizontal direction and extends along the longitudinal direction while maintaining a constant cross-sectional shape.

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

[0022] The horizontal plate and the vertical plate constituting the reinforcing plate can be formed by bending a single sheet of 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 a cross-section of "L" shape or a cross-section of "⊥" shape. 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 a cross-section of "ロ" shape, and further include 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, and the composite material-based plate reinforcing material integrated lightweight structural material according to one aspect of the present invention can be manufactured to include a ladder shape as a whole.

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

[0026] The high-performance heat insulating material may be a vacuum heat insulating material (VIP: Vacuum Insulation Panel).

[0027] The composite material-based plate reinforcing material integrated lightweight structural material according to one aspect of the present invention can 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, so that the connecting portion can be finished airtightly.

[0029] A composite material-based plate-reinforced lightweight structural material with integrated plate reinforcement according to one aspect of the present invention may further include a side edge finishing material for finishing both edges of the top plate and the reinforcement plate, wherein the side edge finishing material is provided in an angle shape having a straight or "￢" shaped cross section, with one end inserted between the top plate and the reinforcement plate and the other end protruding to the outside of the top plate and the reinforcement plate.

[0030] When connecting adjacent lightweight structural members, the opposing side-end finishing members can be structurally joined by welding or bolting.

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

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

[0033] Furthermore, according to another aspect of the present invention for achieving the above objectives, a method for manufacturing a lightweight structural material comprising a flat metal top plate, a plurality of metal reinforcing plates arranged below the top plate at predetermined intervals, including a horizontal plate formed horizontally and a vertical plate bent downward from the horizontal plate, and a core layer formed in the space between the top plate and the reinforcing plates and in the space between adjacent reinforcing plates, is provided, comprising the steps of: filling the space between the top plate and the reinforcing plates and in the space between adjacent reinforcing plates with a non-foaming polymer stock solution; curing the non-foaming polymer stock solution; and the non-foaming polymer stock solution being cured and the formation of the core layer being completed, thereby providing a method for manufacturing a composite material-based plate-reinforced integrated lightweight structural material.

[0034] In the step of filling the non-foaming polymer stock, a space is formed on the upper plate, and after pouring the non-foaming polymer stock, the reinforcing plate is inverted and placed in from above. By pressurizing it to a position where there is a predetermined distance between it and the upper plate, the non-foaming polymer stock overcomes the frictional resistance due to viscosity caused by the pressurizing force of the reinforcing plate and dissolves into the space between it and the reinforcing plate, filling it evenly.

[0035] The amount of the non-foaming polymer concentrate initially poured into the space on the upper plate is at least 2% more than the actual volume occupied by the core layer, and the excess can be pushed out and discharged by the pressurizing force of the reinforcing plate.

[0036] In the step of filling the non-foaming polymer stock solution, the space in which the core layer is formed is sealed, and the non-foaming polymer stock solution is injected into the sealed space using an injection tube. The injection tube can be divided into several small tubes and arranged within the sealed space.

[0037] During the step of filling the non-foaming polymer stock solution, the space in which the core layer is formed is sealed, an injection tube is inserted into one side of the sealed space, and the non-foaming polymer stock solution is injected. At the same time, a vacuum pump can be used on the other side to suck out the air from the sealed space.

[0038] In at least one of the steps of filling the non-foaming polymer stock and curing the non-foaming polymer stock, a magnet can be placed on at least one of the surfaces of the top plate and the reinforcing plate, or a tensile force can be applied by adsorption using a vacuum adsorption device, for the purpose of maintaining flatness and an accurate angle. [Effects of the Invention]

[0039] The composite material-based plate-reinforced lightweight structural material according to the present invention can be effectively applied to thin-plate structures of ships, and can also be universally applied in the construction field (especially to floor structures for construction), and has the following specific effects.

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

[0041] (2) The composite material-based plate-reinforced lightweight structural material according to the present invention is significantly lighter in weight than conventional steel plate structural materials for ships and any other structural material, making it possible to achieve structural weight reduction. In other words, when used as a structure for ships or buildings, it has the effect of reducing the overall weight of the structure.

[0042] (3) The composite material-based plate-reinforced lightweight structural material according to the present invention can be manufactured with a thickness similar to that of general shipbuilding steel plate structural materials, while being based on a composite material, and its form and assembly method are similar to those of general shipbuilding steel plate structural materials, so it can be easily used in the manufacture of ship structures. Preferably, the composite material-based plate-reinforced lightweight structural material according to the present invention can be used as a ship deck structure, and is expected to be particularly useful when used in the manufacture of deck structures for car carriers (PCCs), where weight reduction of the ship is of paramount importance.

[0043] (4) The composite material-based plate-reinforced lightweight structural material according to the present invention can be manufactured as a structure with a significantly thinner thickness compared to other composite material-based structural materials, and can be manufactured at a lower cost than conventional steel plate structural materials used in ships, thus offering advantages in terms of cost.

[0044] (5) The composite material-based plate-reinforced lightweight structural material according to the present invention, being made of a composite material of metal and polymer, can reduce noise and vibration and also have thermal insulation properties, thus having the advantage of being usable not only in the shipbuilding field but also as a structural material for construction. Furthermore, when applied in the construction field, by arranging the lightweight structural material according to the present invention in layers and adding cooling / heating and fire-resistant functions to the space between them, it is possible to realize a multi-functional structure.

[0045] The effects of the present invention are not limited to those described above, and other effects not mentioned can be clearly understood by an ordinary person of the art from the following materials. [Brief explanation of the drawing]

[0046] [Figure 1] Figure 1 shows the sheet metal structural materials mainly used in conventional ships. [Figure 2] Figure 2 shows a first embodiment of the lightweight structural material according to the present invention. [Figure 3] Figure 3 shows a second embodiment of the lightweight structural material according to the present invention. [Figure 4] Figure 4 shows a third embodiment of the lightweight structural material according to the present invention. [Figure 5] Figure 5 shows a fourth embodiment of the lightweight structural material according to the present invention. [Figure 6] Figure 6 shows a fifth embodiment of the lightweight structural material according to the present invention. [Figure 7] Figure 7 shows the first side end finish and connecting structure of the lightweight structural material according to the present invention. [Figure 8] Figure 8 shows the second side end finish and connecting structure of the lightweight structural material according to the present invention. [Figure 9] Figure 9 shows the third side end finish and connecting structure of the lightweight structural material according to the present invention. [Figure 10] Figure 10 shows the first lower end finishing structure of a lightweight structural material according to the present invention. [Figure 11]Figure 11 shows the second lower end finishing structure of the lightweight structural material according to the present invention. [Figure 12] Figure 12 is a diagram illustrating the first manufacturing method for lightweight structural materials according to the present invention. [Figure 13] Figure 13 is a diagram illustrating the second manufacturing method for lightweight structural materials according to the present invention. [Figure 14] Figure 14 is a diagram illustrating the third manufacturing method for lightweight structural materials according to the present invention. [Figure 15] Figure 15 is a diagram illustrating the fourth manufacturing method for lightweight structural materials according to the present invention. [Figure 16] Figure 16 is a diagram illustrating the fifth manufacturing method for lightweight structural materials according to the present invention. [Figure 17] Figure 17 shows a structure in which a high-performance thermal insulation material is included in the core layer of a lightweight structural material according to the present invention. [Figure 18] Figure 18 shows an example in which the lightweight structural material according to the present invention is applied to the floor structure of a building. [Figure 19] Figure 19 shows the first wall connection structure of the lightweight structural material according to the present invention. [Figure 20] Figure 20 shows the second wall connection structure of the lightweight structural material according to the present invention. [Figure 21] Figure 21 shows the third wall connection structure of the lightweight structural material according to the present invention. [Figure 22] Figure 22 shows the fourth wall connection structure of the lightweight structural material according to the present invention. [Figure 23] Figure 23 shows a superimposed structure of lightweight structural materials according to the present invention. [Figure 24] Figure 24 shows a first example of the application of a superimposed structure in which lightweight structural materials according to the present invention are arranged in a superimposed manner. [Figure 25] Figure 25 shows a second example of the application of a superimposed structure in which lightweight structural materials according to the present invention are arranged in a superimposed manner. [Modes for carrying out the invention]

[0047] Details regarding the object, technical configuration, and resulting operation and effects of the present invention will be better understood from the detailed description based on the drawings attached to the specification of the present invention.

[0048] The terms used herein are for illustrative purposes only to describe specific embodiments and are not intended to limit the invention. For example, terms such as “composed of” or “including” as used herein should not be interpreted as necessarily including some of the components or steps described in the invention, but not as not including some of the components or steps, or as potentially including additional components or steps. Furthermore, singular expressions used herein include plural expressions that do not have obviously different meanings in context.

[0049] The present invention will be described in detail below by referring to the attached drawings and describing preferred embodiments of the present invention. The embodiments described below are provided so that the technical concept of the present invention can be easily understood by those skilled in the art, and should not be construed as limiting the present invention, and of course the embodiments of the present invention can have various applications to those ordinary in the art.

[0050] I. Structure of lightweight structural materials

[0051] The lightweight structural material 100 according to the present invention basically includes a metal top plate 110, a metal reinforcing plate 120, and a non-metallic core layer 140 formed between them, and can be composed of a composite material of metal and non-metal, and is characterized in that the downward bending structure of the reinforcing plate 120 and the protruding structure formed by the core layer 140 formed vertically between them function as a plate reinforcement.

[0052] The lightweight structural material 100 according to the present invention can have several embodiments depending on the shape of the downward projection and the manufacturing method. Below, we will refer to Figures 2 to 6 and examine each of the possible embodiments of the lightweight structural material 100 according to the present invention.

[0053] (1) First Embodiment

[0054] Referring to FIG. 2, the first embodiment, which is the most basic form of the lightweight structural member 100 according to the present invention, will be described. Referring to FIG. 2, the lightweight structural member 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 disposed at a certain interval below the upper plate 110 and has a structure bent downward to perform a plate reinforcing function, and a core layer 140 made of a non-metallic material formed in the space between the upper plate 110 and the reinforcing plate 120 and in the space between adjacent reinforcing plates 120.

[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 a form in which 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 a "¬" - shaped cross section and a second reinforcing plate 120b having a "匚" - shaped cross section. The first reinforcing plate 120a is disposed at both ends along the width direction of the lightweight structural member 100, and at least one or more second reinforcing plates 120b can be repeatedly disposed therebetween. The adjacent first reinforcing plate 120a and second reinforcing plate 120b are disposed such that the legs disposed vertically face each other at a predetermined interval.

[0058] The core layer 140 can 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 can be formed of a non-foaming polymer, more preferably a non-foaming polyurethane suitable for elasticity and structural strength. As will be described later, the core layer 140 can be formed by curing the non-foaming polymer stock solution filled in the space.

[0059] The completed lightweight structural material 100 can have a structure including 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 two or more protruding portions can be repeatedly formed at regular intervals. Here, when the lightweight structural material 100 is used to constitute a floor structure such as a deck, the flat plate portion serves as a structural member that primarily contacts the design load. The protruding portion can enhance the structural performance by increasing the strength and rigidity of the flat plate portion formed in the horizontal direction and function as a plate reinforcement to prevent buckling.

[0060] More specifically, in the lightweight structural material 100, the protruding portion can be composed of the leg portions of the reinforcing plates 120 arranged opposite to each other and the core layer 140 filled in the space therebetween. Such a protruding structure can perform the web function of the plate reinforcement.

[0061] On the other hand, when the reinforcing plate 120 is configured in a bent form of "¬" or "匚", it is preferable to bend the metal plate constituting the reinforcing plate 120 by bending. This is to embody a structure that is structurally strong and has no risk of thermal distortion or crack generation due to welding by having a continuous form without interruption between the flat plate portion formed in the horizontal direction and the protruding portion formed in the vertical direction in the lightweight structural material 100.

[0062] (2) Second Embodiment

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

[0064] In this configuration, the reinforcing plate 120 is configured to include a space in the portion that protrudes downward in which the core layer 140 can be filled. Thus, a total of four bending processes are performed on a single reinforcing plate 120.

[0065] This second embodiment, compared to the first embodiment, requires more bending of the reinforcing plate 120, which is more labor-intensive. However, because the reinforcing plate 120, which is manufactured in a "T" shape, already includes a protruding structure, and the lower end of the protruding structure is closed, it is structurally more stable, and the process of forming the core layer 140, which will be described later, can be carried out more smoothly.

[0066] (3) Third Embodiment

[0067] Referring to Figure 4, the lightweight structural material 100 according to the third embodiment of the present invention can have a structure in which the lower end of the downwardly projecting portion is bent horizontally again. That is, in the lightweight structural material 100, the downwardly projecting portion has a cross-section that is approximately "L" shaped.

[0068] In the third embodiment, the projections extending downward from the lightweight structural member 100 can include vertically formed reinforcing portions and horizontally formed reinforcing portions, where the vertical reinforcing portions perform the web function of the plate reinforcing material and the horizontal reinforcing portions perform the flange function of the plate reinforcing material.

[0069] On the other hand, Figure 4 shows a structure in which the core layer 140 is exposed at the edge of the horizontal reinforcement formed at the lower end of the protruding portion. However, this portion may be configured to be closed by a reinforcing plate 120, similar to the second embodiment described above.

[0070] (4) Fourth Embodiment

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

[0072] In the fourth embodiment, the projections protruding downward from the lightweight structural member 100 may include vertically formed reinforcing portions and horizontally formed reinforcing portions, with the vertical reinforcing portions performing a web function for the plate reinforcing material and the horizontal reinforcing portions performing a flange function for the plate reinforcing material, similar to the third embodiment described above.

[0073] The lightweight structural member 100 according to the third and fourth embodiments can function as a more effective plate reinforcement because the section modulus is increased more significantly by the addition of the shape of the downward edge of the protruding portion.

[0074] (5) Fifth embodiment

[0075] Referring to Figure 6, as another embodiment, a fifth embodiment of the lightweight structural material 100 according to the present invention includes a flat metal upper plate 110, a flat metal lower plate 130 positioned parallel to the upper plate 110 at a certain distance below the upper plate 110, a plurality of reinforcing plates 120 positioned 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 space between adjacent reinforcing plates 120, and can be configured in a substantially ladder-like form.

[0076] The reinforcing plate 120 can be arranged at a certain interval so that a space is formed between the upper plate 110, and can also be arranged at a certain interval from the lower plate 130 in the same manner.

[0077] In the fifth embodiment, the reinforcing plate 120 can include a first reinforcing plate 120c having a "匚"-shaped cross-section and a second reinforcing plate 120d having a "ロ"-shaped cross-section. At both ends along the width direction of the lightweight structural member 100, the first reinforcing plate 120c is arranged, and at least one or more second reinforcing plates 120d can be repeatedly arranged therebetween. The intervals between the first reinforcing plate 120c and the second reinforcing plate 120d and between the second reinforcing plates 120d adjacent to each other can be formed to be the same.

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

[0079] In the lightweight structural member 100 according to the fifth embodiment of the present invention, the portion formed in the vertical direction by the reinforcing plate 120 and the core layer 140 performs the web function of the plate reinforcement material, and the structure of the core layer 140 formed in the horizontal direction between the reinforcing plate 120 and the lower plate 130 and the lower plate 130 attached to the lower end thereof can perform the flange function of the plate reinforcement material.

[0080] In the lightweight structural member 100 according to the present invention including the above-described first to fifth embodiments, the protruding portion protruding downward (in the fifth embodiment, the portion formed in a vertical columnar shape by the reinforcing plates 120 facing each other and the core layer 140 formed therebetween can be regarded as the protruding portion) acts to increase the section modulus of the entire structure. The section modulus can be determined by the height, shape, etc. of the protruding portion that functions as a plate reinforcement structure.

[0081] Conventional sheet metal structural materials (see Figure 1), which are mainly used in ship structures and consist only of metal, have a problem in that a plate reinforcing member 20 is welded to the lower side of the upper plate 10 for structural reinforcement. This conventional method has the problem that considerable thermal distortion occurs when the plate reinforcing member 20 is joined by welding.

[0082] However, unlike conventional steel plate structural materials in which the upper plate 10 and plate reinforcing material 20, which function as structural members, are manufactured separately and then joined by welding, the lightweight structural material 100 according to the present invention is constructed in a form in which the flat plate portion and the protruding portion therefrom are manufactured as a single unit and are already incorporated into the plate reinforcing structure itself. Therefore, there is absolutely no risk of thermal distortion occurring due to welding, as in the conventional method.

[0083] Furthermore, even if we consider the case where the upper plate 10 and the plate reinforcing member 20 are bolted together instead of welded together when manufacturing conventional steel plate structural materials, additional hole construction and localized structural reinforcement work are required for bolting the upper plate 10 and the plate reinforcing member 20 together. In contrast, the lightweight structural material 100 according to the present invention, in which the plate reinforcing structure is formed integrally, does not require any of the above-mentioned additional processes, and therefore can have structurally stable performance.

[0084] Furthermore, since the lightweight structural material 100 according to the present invention already includes a plate reinforcement structure with protruding parts, the thickness of the upper plate 110 and the reinforcing plate 120 can be made much thinner compared to cases where welding of the plate reinforcement structure is required, making it possible to manufacture an optimized composite structure.

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

[0086] The thickness of the top plate 110, reinforcing plate 120, bottom plate 130, and core layer 140 constituting 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 that of a typical steel plate structural material for ships.

[0087] Specifically, the thickness of the top plate 110 and 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 connecting individual modules of the lightweight structural material 100 according to the present invention to each other, welding work may be required. Therefore, the thickness of the top plate 110 and reinforcing plate 120 that constitute the outer plate of the lightweight structural material 100 should be formed to be 0.4 mm or more, which facilitates laser welding. Furthermore, in order to achieve structural weight reduction, which is one of the technical challenges of the present invention, the thickness of the top plate 110 and reinforcing plate 120 should be 10 mm or less. Therefore, the present invention presents a more preferable thickness of 0.4 to 10 mm for the metal plates constituting the top plate 110 and reinforcing plate 120. When a bottom plate 130 is further included, as in the fifth embodiment, the thickness of the bottom plate 130 follows the thickness of the top 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 a variety of ways, from 3 to 40 mm. In this case, the core layer 140 may be formed with different thicknesses in the portion formed horizontally and the portion formed vertically (the portion formed between the opposing reinforcing plates 120).

[0089] In other words, the lightweight structural material 100 according to the present invention may have the same thickness of core layer 140 in the flat portion and the same thickness of core layer 140 in the protruding portion, but it can also be adjusted to be different. When different thicknesses are to be formed, it is preferable to make the thickness of the core layer 140 in the protruding portion, which functions as a plate reinforcing material, thinner than the thickness of the core layer 140 in the flat portion.

[0090] On the other hand, as mentioned above, there are some members whose names should not be confused with each other. However, this does not mean that the top plate 110 of the lightweight structural material 100 according to the present invention must have structural performance equivalent to that of a general shipbuilding steel plate structural material top plate 10. Rather, it should be understood that the lightweight structural material 100 according to the present invention includes the top plate 110, the reinforcing plate 120, and the core layer 140 formed between them, and that the flat plate portion formed horizontally and in direct contact with the design load can be designed to have structural performance equivalent to that of a general shipbuilding steel plate structural material top plate 10. The same applies when determining the thickness of the reinforcing plate 120 and the core layer 140 formed between them that constitute the plate reinforcement structure.

[0091] In other words, in the lightweight structural material 100 according to the present invention, the entire flat plate portion, including the top plate 110, the reinforcing plate 120, and the core layer 140 formed between them, must be made to correspond to the top plate 10 of a general shipbuilding steel plate structural material, and structural strength must be considered. Therefore, the thickness of the top plate 110 in the lightweight structural material 100 according to the present invention, which is designed to have structural performance equivalent to that of a general shipbuilding steel plate structural material, will be much thinner than the corresponding top plate 10 in a general shipbuilding steel plate structural material. For example, a composite structure of the lightweight structural material 100 according to the present invention that is equivalent to a 6 mm top plate 10 of a general shipbuilding steel plate structural material can be formed with a top 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] Furthermore, in the lightweight structural material 100 according to the present invention, the spacing (d) between the protruding structures that serve 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 spacing (d) between the protruding parts of the lightweight structural material 100 according to the present invention may be formed at approximately 600 to 900 mm, similar to the spacing of general shipbuilding steel plate structural materials. If the thinness of the lightweight structural material 100 is not achieved (for example, if the thickness is increased by arranging a high-performance thermal insulation material 141 inside the core layer 140, as described later), the spacing (d) between the protruding structures can be increased to 1,500 to 3,000 mm.

[0093] The width of the lightweight structural material 100 according to the present invention can be changed depending on the number of protrusions formed. For example, when the spacing between protrusions is uniformly 700 mm, a structure having 3 to 4 protrusions can be formed with an overall width of approximately 2,100 to 3,500 mm.

[0094] The height (h) of the protrusion extending downward from the lightweight structural member 100 can be formed at a level that has equivalent structural performance to general shipbuilding steel plate structural members, by comparing the section modulus of the entire structure, and can be similar to or lower than conventional plate reinforcements made solely of metal. For example, if the height of a plate reinforcement of a conventional steel plate structural member that aims to embody 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 mentioned above, as the shape of the protrusion progresses from a simple linear "l" shape to an "L" shape, a "⊥" shape, and a ladder shape, the section modulus of the entire structure increases, and therefore the height (h) of the protrusion can be made even lower. Here, the height (h) of the protrusion can mean the height from the lowest end of the reinforcing plate 120 to the lower surface of the reinforcing plate 120 that forms a flat plate portion horizontally.

[0095] Furthermore, as in the third and fourth embodiments (see Figures 4 and 5), when the lightweight structural material 100 according to the present invention is configured to further include a horizontal reinforcing portion formed horizontally at the lower end of the protruding portion, the width (w) of the horizontal reinforcing portion can also be formed to an equivalent size similar to that of conventional plate reinforcing materials for steel plate structural materials, 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 ranging from approximately 3 m in length to 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 of up to 14 m is that the core layer 140, which is made of a non-foaming polymer with a specific gravity of 0.8 to 1.8 and is much lighter than metal, is firmly joined between the top plate 110 and the reinforcing plate 120, providing basic structural performance, while the protruding portion that extends downward from the lightweight structural material 100 functions as a plate reinforcement.

[0097] Furthermore, it is noteworthy that the lightweight structural material 100 according to the present invention, which is manufactured in a long-span structure, can exhibit structural performance equivalent to or better than general shipbuilding steel plate structural materials or reinforced concrete for buildings, without the need to add separate reinforcing materials in the direction that crosses the width of the structural material. That is, in the general shipbuilding steel plate structural material shown in Figure 1, the plate reinforcing material 20 should be configured to include both a Longitudinal girder 21 that reinforces the longitudinal structure and a Transverse frame 22 that reinforces the transverse structure. However, in the lightweight structural material 100 according to the present invention, it is sufficient for a number of protrusions to be formed only along the longitudinal direction at the bottom of the plate structure, and there is no need to provide a separate reinforcing structure along the width direction that crosses it.

[0098] The lightweight structural material 100 according to the present invention can be manufactured to satisfy a predetermined deflection standard, which can be achieved by adjusting / selecting the height and shape of the protrusions that function as plate reinforcements, as described above, to form the overall section modulus of the structure to 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 thickness of the top plate 110 and the reinforcing plate 120 is formed to be 1 mm each, and the core layer 140 is formed with a thin core of 5 mm, the live load is 200 kgf / m 2Furthermore, in order to satisfy the L / 480 deflection standard while forming a 600mm gap between the protruding parts under the condition of fixing both ends, the height (h) of the protruding part can be calculated as approximately 125mm in the case of an "l" shape, approximately 100mm in the case of a "⊥" shape where a horizontal reinforcing part with a width (w) of 100mm is formed, and approximately 65mm in the case of a ladder shape.

[0100] In the aforementioned deflection standard, "L" represents the length (span) of the lightweight structural member 100. To satisfy the L / 480 deflection standard, the central portion of the lightweight structural member 100 must not deflect by more than 1 / 480 of its total length. As in the example given above, when the lightweight structural member 100 according to the present invention is manufactured with a length (span) of 6m and both ends are fixed, the L / 480 deflection standard is satisfied only when the maximum deflection is 6,000 / 480 = 12.5 (mm) or less.

[0101] In other words, the structural performance of the lightweight structural material 100 to meet the deflection standard can be realized through adjustments to the height and shape of the protruding parts. Furthermore, by providing a certain level of adhesive strength between the top plate 110, the reinforcing plate 120, and the core layer 140, the realization of the aforementioned structural performance of the lightweight structural material 100 can be further facilitated.

[0102] Specifically, the non-foaming polymer constituting the core layer 140 has adhesive properties of its own, and as described later, during the curing process of the liquid non-foaming polymer stock, the surfaces in contact with the top plate 110 and the reinforcing plate 120 are tightly bonded. The present invention can provide an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, between the top plate 110 and the core layer 140, and between the reinforcing plate 120 and the core layer 140. If a bottom plate 130 is further included, as in the fifth embodiment, the same adhesive strength can also be provided between the bottom plate 130 and the core layer 140.

[0103] As will be described later, the lightweight structural material 100 according to the present invention may have its side or bottom ends finished with non-metallic or metallic finishing members in the future for structural bonding with other modules, or for optimizing the structural strength required by the module itself or for reinforcement in terms of fatigue strength. In this case as well, it is preferable to provide a bonding strength of at least 1 MPa (more preferably 6 MPa or more) between the non-foaming polymer, which is the internal core, and the finishing material.

[0104] As described above, the lightweight structural material 100 according to the present invention has material characteristics consisting of a composite material of a metal top plate 110 and reinforcing plate 120 and a core layer 140 made of a non-foaming polymer. In addition, by configuring the lightweight structural material 100 itself to include a plate reinforcing structure, it is possible to realize an ultra-lightweight structure with remarkably excellent structural performance.

[0105] Specifically, the lightweight structural material 100 made from the composite material according to the present invention can achieve equivalent structural performance with approximately 50-60% of the weight of general steel plate structural materials mainly used in the shipbuilding industry, and can achieve equivalent structural performance with approximately 15-25% of the weight of reinforced concrete mainly used in the building industry.

[0106] Furthermore, according to general standard carbon emission tables, steel plates and non-foaming polymers are known to emit 2-3 kg of CO2 per kilogram (kg). However, the specific gravity of non-foaming polymers is at the level of 0.8-1.8, which is far lower than the specific gravity of steel plates (7.85). Therefore, carbon emissions generated during the structural fabrication process are significantly reduced, potentially resulting in a reduction of approximately 50% compared to conventional methods.

[0107] II. Finishing and connecting structures for lightweight structural materials

[0108] In the following sections, we will examine the finishing and connecting structures of the lightweight structural material 100 according to the present invention, with reference to Figures 7 to 11.

[0109] (1) First side end finish and connecting structure

[0110] First, referring to Figure 7, in the lightweight structural material 100 according to the present invention, a first side edge finishing material 151 made of a metal or non-metallic material can be inserted and positioned between the upper plate 110 and the reinforcing plate 120 at both end surfaces formed horizontally. Here, when the first side edge finishing material 151 is made of a non-metallic material, it is preferable that it is made of a material that can achieve a bonding strength of at least 1 MPa (more preferably 6 MPa or more) with the non-foaming polymer which is the internal core.

[0111] Furthermore, adjacent lightweight structural members 100 can be joined together by laser welding of the upper plates 110 and reinforcing plates 120, which are arranged to abut each other. As mentioned above, laser welding has the advantage of less thermal distortion, but it has the problem that its efficiency decreases as the thickness increases, making it difficult to apply to general steel plate structural materials for ships that are 6 mm or thicker. However, the present invention uses metal plates thinner than 6 mm (for example, 0.5 to 5 mm) as the upper plates 110 and reinforcing plates 120, which has the advantage of being suitable for laser welding.

[0112] Furthermore, in this embodiment, the first side-edge finishing material 151 can be positioned by being pushed inward by a predetermined distance from the lightweight structural material 100. This allows for the formation of a space (S) between the opposing first side-edge finishing materials 151 positioned on each lightweight structural material 100 when two or more lightweight structural materials 100 are positioned in contact with each other in order to connect them. By injecting a non-foaming polymer stock (more preferably a non-foaming polyurethane stock) into this space (S) and allowing it to harden, the connection portion of the adjacent lightweight structural materials 100 can be finished securely. At this time, an additional effect can be achieved in which an additional bonding force is imparted between the lightweight structural materials 100 due to the adhesive strength of the non-foaming polymer itself.

[0113] Alternatively, the first side edge finishing material 151 may be removed, leaving the non-foaming polymer core layer 130 exposed. However, even in this case, it is possible to similarly apply the method of forming a predetermined space (S) at the part where the lightweight structural material 100 is connected, injecting the non-foaming polymer raw material into the space (S), and finishing it to an airtight finish.

[0114] (2) Second side end finish and connecting structure

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

[0116] In this embodiment, the second side end finishing material 152 can be made of a metal plate having a straight cross-section and a thickness corresponding to that of the core layer 140, with one end inserted into the interior of the lightweight structural material 100 and the other end protruding and exposed to the outside of the lightweight structural material 100.

[0117] The second side end finishing material 152 that protrudes outward can be structurally connected to the second side end finishing material 152 provided on the adjacent lightweight structural material 100 side by welding or bolting. When the side end of the lightweight structural material 100 is finished with a metal material having a predetermined thickness, as in this embodiment, it is possible to apply universal welding such as CO2 welding, and in addition to welding, mechanical connection methods using bolts, etc., can also be applied, which has the advantage of excellent design flexibility. (3) Third side end finishing and connecting structure

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

[0119] The third side end finishing and connecting structure of the lightweight structural member 100 according to the present invention is similar to the second side end finishing and connecting structure described just above. However, unlike the second side end finishing member 152 described above, which is simply provided in a straight line shape, the third side end finishing member 153 is provided in an angle shape having a "￢" shaped cross section.

[0120] In this embodiment, when attempting to connect two or more lightweight structural members 100 finished with third end finishing members 153, the third end finishing members 153 provided on each of the adjacent lightweight structural members 100 can be structurally joined by welding or bolting, etc., with the third end finishing members 153 coming into contact with each other (it is also possible to apply both welding and bolting). In the case where the cross section of the third end finishing member 153 is provided in the shape of a "￢", as in this embodiment, the presence of a leg makes it easier to apply the bolting method.

[0121] (4) Lower edge finishing structure

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

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

[0124] Furthermore, in the protruding portions of the lightweight structural material 100 according to the present invention, even if the edges of the vertical structures (vertical reinforcement portions) that function as webs of the plate reinforcement material and the edges of the horizontal structures (horizontal reinforcement portions) that function as flanges are not finished with metal, the cross-sectional moment of the structure remains almost the same, and therefore does not significantly affect the overall structural performance. In other words, in terms of optimizing structural performance, there is no significant difference whether the edges of the protruding portions are finished with metal or left unfinished, exposing the non-foaming polymer core. Therefore, the suitability of the aforementioned side edge or bottom edge finishing structure can be determined by considering whether there is a connection between modules of adjacent lightweight structural material 100 or other special purpose.

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

[0126] Furthermore, the aforementioned finishing members (151 / 152 / 153 / 154 / 155) can be inserted between the top plate 110 and the reinforcing plate 120, and the contacting surfaces can be bonded with an adhesive. The surfaces in contact with the core layer 140 can also be bonded by the adhesive strength of the non-foaming polymer itself that forms the core layer 140. Even when the finishing material (151 / 152 / 153 / 154 / 155) is made of metal, sufficient strength can be obtained simply by inserting and bonding without the need for welding. However, in order to prevent peeling of the bonded surfaces, an adhesive strength of 1 to 10 MPa, more preferably 6 MPa, can be applied between the top plate 110 and the reinforcing plate 120 and the finishing members (151 / 152 / 153 / 154 / 155), as described above.

[0127] In the lightweight structural material 100 according to the present invention, the top plate 110 and reinforcing plate 120 are formed to be very thin, so thermal distortion can be minimized by applying laser welding. In particular, since a core layer 140 is formed by curing after filling with a non-foaming polymer, providing structural rigidity, it is also possible to perform laser welding afterward, thus minimizing welding distortion.

[0128] Furthermore, in the lightweight structural material 100 according to the present invention, the reinforcing plate 120 made of metal material that constitutes the protruding portion is attached to the internal core layer 140 with an adhesive strength of 1 MPa or more, more preferably 6 MPa or more. Therefore, an integrated plate reinforcing material function can be realized without separate welding or with minimal tag welding.

[0129] III. Manufacturing Methods for Lightweight Structural Materials

[0130] Next, referring to Figures 12 to 16, we will examine the specific manufacturing method of the lightweight structural material 100 according to the present invention.

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

[0132] However, forming a non-foaming polymer structure on such thin walls is not practically easy. This is because the undiluted non-foaming polymer has a viscosity greater than that of lubricating oil before curing, so if the space to be filled is too narrow, frictional resistance makes injection difficult, and it is difficult to spread evenly within the space. Considering the characteristics of manufacturing composite materials consisting of metal and non-foaming polymer, according to a certain classification society's regulations that specify the basic performance and structural requirements of ships, it is recommended that the metal plate be at least 3 mm thick, and the core made of non-foaming polymer be at least 15 mm thick, and that separate approval be obtained if these are not followed.

[0133] The manufacturing method described below relates to the case in which the core layer 140 of a lightweight structural material 100 is formed from a non-foaming polymer (for example, non-foaming polyurethane), and is proposed in particular to solve the aforementioned manufacturing difficulties, namely, the difficulty in forming a thin core layer 140 composed of a non-foaming polymer. More preferably, it presents a method that enables even filling of the space with a non-foaming polymer and obtaining a uniform core layer 140 even when the core layer 140 is formed with a thickness of 15 mm or less.

[0134] (1)First manufacturing method

[0135] Referring to Figure 12, the first manufacturing method for the lightweight structural material 100 according to the present invention is a method in which a non-foaming polymer stock is poured onto a reinforcing plate 120 to fill it, and then the top plate 110 is placed over it. If the lower end of the reinforcing plate 120 is open, the lower end can be formed as a sealed structure using seaming, and seaming can also be applied to the sides of the reinforcing plate 120 so that the non-foaming polymer stock fills the space on the reinforcing plate 120 to a predetermined level. If the lower end of the reinforcing plate 120 is formed as a closed structure, or if it is finished with a separate finishing member, it may not be necessary to apply seaming, and this is also true for other manufacturing methods described later.

[0136] On the other hand, this manufacturing method does not involve injecting the non-foaming polymer concentrate into a sealed space, but rather pouring it into an open space to fill it. Because the work is carried out in an open cavity, bubbles can be formed by the contact between the non-foaming polymer concentrate 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 to remove the bubbles is required.

[0137] To this end, this manufacturing method involves embedding a non-foaming polymer concentrate in an amount at least 2% greater than the volume actually occupied by the core layer 140 on the reinforcing plate 120, and when covering it with the top plate 110, not covering the entire plate at once, but applying a slight incline or bend, and covering it while pressing down on the surface of the non-foaming polymer concentrate. That is, by using the top plate 110 to cover the surface of the non-foaming polymer concentrate while pressing it from one side to the other, the excess non-foaming polymer concentrate can be pushed out of the panel, and air 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 purpose of overflow and air vents of the non-foaming polymer concentrate.

[0138] (2)Second manufacturing method

[0139] The process of the second manufacturing method for the lightweight structural material 100 according to the present invention will be explained with reference to Figure 13.

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

[0141] Then, with the non-foaming polymer concentrate poured into the space of the upper plate 110, the reinforcing plate 120 is inserted from above and pressed down. The reinforcing plate 120 can be pressurized using a hydraulic device or the like until the distance between it and the upper plate 110 is set to a predetermined distance. At this time, a spacer can be placed between the upper plate 110 and the reinforcing plate 120 to maintain the thinness of the design.

[0142] The non-foaming polymer concentrate filling the space in the upper plate 110 can dissolve into the vertical space (a thin gap that acts as a web for the plate reinforcement) formed between the legs of the opposing reinforcing plates 120 by the force pressing against them. At this time, since the non-foaming polymer concentrate fills the space in a volume greater than the volume actually occupied by the core layer 140, the excess amount can be pushed out and discharged, and air bubbles can also be removed through this process.

[0143] The non-foaming polymer stock, evenly filled between the top plate 110 and the reinforcing plate 120, hardens over time, forming a core layer 140. The formation of the core layer 140 completes the production of the lightweight structural material 100 according to the present invention.

[0144] The first and second manufacturing methods described above do not involve injecting the non-foaming polymer concentrate into a sealed space, but rather pouring it into an open space to fill it. These methods have the advantage of being able to form thin-walled plate reinforcement structures by overcoming the frictional resistance generated when injecting the non-foaming polymer concentrate by applying pressure, and also allowing the worker to visually confirm that the non-foaming polymer concentrate is properly filling the overall structure corresponding to the core layer 140.

[0145] (3) Third manufacturing method

[0146] Referring to Figure 14, the third manufacturing method for the lightweight structural material 100 according to the present invention uses a method 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, the injection tube for injecting the non-foaming polymer stock solution is not just one, but is divided into several small tubes.

[0147] Typically, non-foaming polymers undergo a chemical reaction when two liquids, ISO and an organic compound such as polyol, are mixed, and curing begins at this stage. Since this chemical reaction takes only a few minutes, the injection of the non-foaming polymer concentrate must also be completed within a few minutes. Furthermore, because the non-foaming polymer concentrate is inherently viscous, it can be difficult to spread it evenly within a few minutes.

[0148] This manufacturing method is designed to solve the aforementioned process difficulties by dividing the injection pipe for injecting the non-foaming polymer stock into several smaller pipes and tightly arranging these within the space where the core layer 140 is to be formed. This allows the non-foaming polymer stock to 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 are unsealed areas between boards, a sealed space can be formed using seaming. If a separate finishing material is used, the finishing material can then seal that area. This can be applied similarly to other manufacturing methods.

[0150] (4) Fourth manufacturing method

[0151] Referring to Figure 15, the fourth manufacturing method for the lightweight structural material 100 according to the present invention involves forming a sealed space between the upper plate 110 and the reinforcing plate 120, and injecting a non-foaming polymer stock solution into the sealed space. This method involves using a vacuum pump (VP) to remove air from the sealed space while injecting the solution.

[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 end and a non-foaming polymer stock solution is injected, while on the other end, a vacuum pump (VP) is used to suck air out of the sealed space.

[0153] This manufacturing method not only allows for the injection of a non-foaming polymer concentrate into thin walls while overcoming frictional resistance due to the pressure difference between the inside and outside of a sealed space, but also has the advantage of enabling rapid injection through the suction power of a vacuum pump (VP).

[0154] (5) Fifth manufacturing method

[0155] The top plate 110 and reinforcing plate 120 used in the manufacture of the lightweight structural material 100 according to the present invention use metal plates that are far thinner than the steel plates commonly used for ships. This presents a technical challenge in the manufacturing process, specifically because the metal plates are so thin that it is difficult to maintain the shape and control the flatness of the plates before and during the core (non-foaming polymer) filling process.

[0156] Conventionally, spacers were used to maintain the shape (or spacing) during the process of filling the core between the two plates. Also, when a non-foaming polymer is used as the core, it has the characteristic of slightly expanding during the curing process, so the upper plate is sometimes pressed down with considerable load. However, as in the present invention, 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, it is difficult to maintain the shape and flatness of the plates using the conventional method described above.

[0157] Furthermore, development occurs in which the upper plate flexes due to its own weight. In this case, if the core is formed to be sufficiently thick, the strength of the chemical reaction is also strong, and the upward force can be used to push up the flexed upper plate again. However, as in the present invention, if the core layer 140 is formed to be thin, the upward force is weak and is not sufficient to restore the flexing of the upper plate 110 due to its own weight.

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

[0159] The fifth manufacturing method for the lightweight structural material 100 according to the present invention was proposed to solve the aforementioned difficulties in the manufacturing process. While the first to fourth manufacturing methods described above are methods related to the filling of non-foaming polymers, the fifth manufacturing method can be seen as a method related to maintaining the overall shape and flatness of the structural material before and during the injection of the non-foaming polymer.

[0160] Specifically, as shown in Figure 16, when a non-foaming polymer concentrate is filled in the space between the top plate 110 and the reinforcing plate 120, and a magnet (M) is placed on the upper surface of the top plate 110, the magnetic field generated by the magnet (M) causes the upper surface of the top plate 110 to come into close contact with the magnet (M), allowing it to maintain a flat state.

[0161] For reference, in the embodiment shown in Figure 16, the process proceeds with the reinforcing plate 120 and the top plate 110 sequentially stacked on a surface plate, so the magnet (M) is placed on the upper surface of the top plate 110. If the process proceeds with the top plate 110 and the reinforcing plate 120 reversed, the non-foaming polymer stock solution may be placed on top of the reinforcing plate 120, and the magnet (M) may be placed on the upper surface of the reinforcing plate 120.

[0162] Here, the term "magnet (M)" can be understood as a concept that includes electromagnets and all magnetic materials capable of generating a force that attracts metal. The magnet (M) does not need to be sized to correspond to the entire area of ​​the plate on which the flatness should be maintained; even if it occupies only a portion of the area, the effect of flattening the entire plate can be observed. Furthermore, multiple magnets (M) can be placed on the plate, and if only one magnet (M) is used, it is preferable to place it in the center of the plate.

[0163] Furthermore, magnets (M) can be placed not only horizontally but also vertically on the sides of the reinforcing plate 120 using the same principle, thereby maintaining flatness and obtaining the desired bending angle.

[0164] In this case, the magnet (M) can be included within a work jig or surface plate that fixes the positions of the top plate 110 and the reinforcing plate 120. The drawing shows that only the magnet (M) that applies tensile force to the reinforcing plate 120 is included within the surface plate, but it is obvious that the magnet (M) that applies tensile force to the top plate 110 can also be included within the work jig or surface plate. In this case, even without providing a separate gripping part in the work jig or surface plate to fix the top plate 110 or the reinforcing plate 120, the incidental effect of easily gripping the top plate 110 or the reinforcing plate 120, which are made of metal plates, due to the pulling force of the magnet can also be enjoyed.

[0165] Furthermore, this manufacturing method can also be implemented using a vacuum adsorption device instead of a magnet (M). Specifically, by using a vacuum adsorption device to adsorb a specific part of the plate whose flatness should be maintained, and applying tensile force, the shape of the structural material and its flatness can be maintained.

[0166] Similar to the case where a magnet (M) is used, a vacuum adsorption device can perform the flatness maintenance function even if it only provides an adsorption force to a portion of the plate rather than the entire area, and it is preferable to adsorb the central part of the plate where the flatness to be maintained is to be maintained. It is also possible to apply multiple vacuum adsorption devices to a single plate.

[0167] The lightweight structural material 100 according to the present invention, manufactured using the fifth manufacturing method described above, has a flat surface and maintains a uniform thickness throughout, thereby achieving uniform structural performance. Furthermore, by resolving the flatness problem during the manufacturing process, the amount of spacers placed between the top plate 110 and the reinforcing plate 120 is greatly reduced, resulting in reduced manufacturing time and costs.

[0168] In accordance with the thickness and edge treatment method used to form the structure of the lightweight structural material 100 according to the present invention, two or more of the above-described manufacturing methods 1 to 5 can be applied in parallel. For example, while the second manufacturing method is carried out in a sealed space that is not an open cavity, it is possible to remove the air from the sealed space using the vacuum pump of the fourth manufacturing method. It is also possible to apply the vacuum pump of the fourth manufacturing method while injecting a non-foaming polymer stock solution using several injection pipes, as in the third manufacturing method. In the case of the fifth manufacturing method, since it is a method applied to maintain the shape and flatness of the structural material, it can be said that it can be carried out in parallel with any of the other manufacturing methods.

[0169] Furthermore, thin-walled non-foaming polymers require more time to cure than thick-walled non-foaming polymers because their absolute capacity for chemical reactions is smaller. In particular, during periods of low temperature, such as winter, the rate of intermolecular chemical reactions necessary for curing also decreases, resulting in longer curing times, or in extreme cases, failure to cure at all. To prevent this, the surface of the manufacturing jig can be equipped with heating wires or thermal piping equipment to raise the temperature, and this is a measure that can be applied to all manufacturing methods.

[0170] IV. Additional Examples of Lightweight Structural Materials

[0171] On the other hand, when constructing the core layer 140 of the lightweight structural material 100 according to the present invention, it is also possible to use additional high-performance thermal insulation material that already embodies thermal insulation and structural performance. In this case, by additionally placing high-performance thermal insulation material with low thermal conductivity between the top plate 110 and the reinforcing plate 120, it becomes possible to achieve excellent thermal insulation performance.

[0172] More specifically, as shown in Figure 17, the core layer 140 can be formed by placing a high-performance thermal insulation material 141 with a thermal conductivity lower than 0.02 W / mK together with a non-foaming polymer between the top plate 110 and the reinforcing plate 120. For example, when the core layer 140 is formed to include a vacuum insulation panel (VIP) with a thermal conductivity of 0.004 W / mK, the total thickness of the lightweight structural material 100 is expected to increase to 20-40 mm, but in terms of thermal insulation, it is possible to achieve thermal insulation performance that is 6-10 times better than that of a typical EPS (Expanded Polystyrene) insulation material. Moreover, due to the properties of the composite material, the structural strength increases in proportion to the square or cube of the increase in thickness, so excellent structural performance can be achieved despite being lightweight.

[0173] Furthermore, when the vacuum insulation material is contained within a non-foaming polymer, the vacuum insulation material can be more effectively protected from external impacts, and the airtight structure of the non-foaming polymer completely blocks gas from entering or leaving the vacuum insulation material, effectively extending the lifespan of the vacuum insulation material to almost perpetual.

[0174] When the core layer 140 is composed solely of a non-foaming polymer, it has the advantage of being able to be manufactured with a very thin thickness optimized for lightweight structural material 100. When a high-performance insulating material 141, such as a vacuum insulating material, is added along with the non-foaming polymer, it has the advantage of being simpler in terms of manufacturing the lightweight structural material 100 (since the non-foaming polymer concentrate is applied to the surface of the high-performance insulating material 141 and used like an adhesive) and providing superior insulating performance. 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 a non-foaming polymer alone or to use a high-performance insulating material 141 in parallel.

[0175] For reference, if the core layer 140 is constructed solely from the high-performance insulation material 141, the bonding force with the top plate 110 and the reinforcing plate 120 is weak, making it difficult to ensure sufficient structural performance. Only when the non-foaming polymer surrounding the high-performance insulation material 141 is firmly fixed between the top plate 110 and the reinforcing plate 120 by adhesive can the lightweight structural material 100 of the present invention achieve satisfactory structural performance.

[0176] V. Examples of applications for lightweight structural materials

[0177] The lightweight structural material 100 according to the present invention can be used to form ship structures or floor, ceiling, and wall structures of buildings. Preferably, the lightweight structural material 100 according to the present invention can be used as a deck structure of a ship. Furthermore, the lightweight structural material 100 according to the present invention can be installed on the upper or lower part of a concrete slab that separates the upper and lower floors of a building and used as a floor or ceiling structure, and of course can be applied to the wall structure of a building as needed. Below, specific examples of applications 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 constructing the floor structure of ship decks and ship deckhouses. In particular, the lightweight structural material 100 according to the present invention is expected to be extremely useful in the shipbuilding industry, especially when applied to the manufacture of car decks of car carriers (PCCs), and is also effective in forming the floor structure of ship deckhouses.

[0180] When the lightweight structural material 100 according to the present invention is used as a ship structural material, it is possible to solve the conventional problem of thermal distortion during welding.

[0181] Traditionally, to construct ship decks, the general steel plate structural material shown in Figure 1 has been primarily used. As mentioned earlier, in this case, the welding of plate reinforcing members 20 beneath the upper plate 10, which acts as a structural member, has made it impossible to avoid the problem of serious thermal distortion. Furthermore, considering only the structural performance of a normal ship deck, the upper plate 10 of the steel plate structural material should be formed with a thickness of approximately 6 mm. However, considering the thermal distortion caused by welding the plate reinforcing members 20, the thickness of the upper plate 10 is frequently increased by about 10 mm from the outset. However, even with an increased thickness of the upper plate 10, the problem of thermal distortion caused by welding the plate reinforcing members 20 still persists, and in reality, a considerable amount of man-hours are spent on corrective work through heat processing after most of the plate reinforcing members 20 have been welded.

[0182] However, the lightweight structural material 100 according to the present invention has a form in which protrusions that function as plate reinforcement members are already incorporated into the structure, and does not require welding to attach the plate reinforcement members. Therefore, the amount of welding required in the entire process and the resulting thermal distortion can be greatly reduced, and thus the problem of thermal distortion caused by welding of steel plate structural materials, which have been mainly used in the shipbuilding industry until now, can be fundamentally solved.

[0183] Furthermore, in this invention, when connecting adjacent lightweight structural members 100, the amount of thermal distortion of the entire plate can be greatly reduced because the finishing materials made of metal are welded together, or the lightweight structural members 100, whose rigidity is already ensured by the core layer 140 formed inside, are welded together.

[0184] Furthermore, the lightweight structural material 100 according to the present invention, which is composed of composite materials, can achieve equivalent structural performance with a weight that is 40-50% lighter than conventional steel plates, thus greatly contributing to the weight reduction of ships.

[0185] (2) Building structure

[0186] The lightweight structural material 100 according to the present invention has a thermal conductivity of 0.2 to 0.4 W / mK, similar to high-density wood, because the space between the top plate 110 and the reinforcing plate 120 is almost entirely filled with a non-foaming polymer. This means that it has significantly better thermal insulation performance than general steel plate structural materials (k=83 W / mK) mainly used for ships, and even better thermal insulation performance than reinforced concrete (k=1.6 W / mK) used for buildings. Furthermore, the lightweight structural material 100 according to the present invention also has excellent performance in terms of vibration / noise reduction due to the role of the elastic non-foaming polymer, making it suitable not only for shipbuilding structures but also for land-based floors and wall structures.

[0187] Typically, the lightweight structural material 100 according to the present invention can be structurally connected to a wall body at both ends along its longitudinal direction to form the floor and ceiling structure of a building. Below, we will sequentially examine examples of how the lightweight structural material 100 according to the present invention is utilized as a floor and ceiling structure for a building.

[0188] A. Building floor structure (double floor)

[0189] The lightweight structural material 100 according to the present invention can be used in the floor structure of a building, and in particular, since it can be manufactured as a long-span structure, it can be very useful in forming a double-floor structure of a building.

[0190] Referring to Figure 18, the lightweight structural material 100 according to the present invention can be fixed to the wall of the upper floor of the building at both edges along its longitudinal direction, and at this time it can be positioned above the concrete slab that constitutes the floor of the upper floor with a slight gap, thereby realizing a double floor structure.

[0191] Generally, in multi-story buildings such as apartments, houses, officetels, and office buildings, the upper and lower floors are separated by a concrete slab. This concrete slab is used as the floor on the upper floor and as the ceiling on the lower floor. In other words, in typical multi-story buildings, the floor structure of the upper floor forms the ceiling structure of the lower floor, and a single concrete slab is shared between two floors. As a result, these buildings are fundamentally vulnerable to noise transmission.

[0192] The most widely used method to solve this inter-floor noise problem is the double-floor structure. However, the conventional double-floor structure, as it is generally known, is a structure in which a lightweight floor is installed on top of a concrete slab, that is, a method that creates two floors and blocks sound transmission by providing an air layer between them.

[0193] However, in such conventional double-floor structures, the structural strength of the lightweight floor is not as strong as that of a concrete floor. Therefore, dozens to hundreds of support structures are required to support the space between the lightweight floor and the concrete slab, and thus the transmission of noise and vibration through numerous support structures cannot be ignored. In addition, there are problems such as increased installation time and costs due to the requirement to install a large number of support structures.

[0194] However, since the lightweight structural material 100 according to the present invention can be manufactured as a long-span structure, sufficient structural performance can be ensured by fixing only both edges along the longitudinal direction to the building wall, and thus a robust and perfect double-floor structure can be realized without a separate lower support structure.

[0195] In other words, when the upper floor is formed with the lightweight structural material 100 according to the present invention and a double floor structure is realized, there is no need to provide a separate support base on the concrete slab to support the lightweight structural material 100. Therefore, the upper floor and the concrete slab are structurally completely separated, making it possible to realize a double floor structure that is very effective in reducing inter-story noise.

[0196] Next, with reference to Figure 18, the effect of reducing inter-story noise by applying the lightweight structural material 100 according to the present invention will be explained in more detail.

[0197] Normally, inter-story noise can be divided into two categories: primary transmission of weight or frictional impact sound generated on the upper floor through the floor structure, and secondary transmission from the upper floor through the wall structure. However, in the double-floor structure realized using the lightweight structural material 100 according to the present invention, impact sound generated on the lightweight structural material 100 side that constitutes the upper floor on the upper floor is converted into sound and transmitted to the concrete slab below. In other words, since the impact sound is transmitted by sound energy rather than by direct vibration, the total amount of energy transmitted to the lower floor can be greatly reduced.

[0198] Furthermore, vibrations transmitted from the lightweight structural material 100 that constitutes the upper floor on the upper floor through the wall are not immediately transmitted to the ceiling finishing material on the lower floor, but are first transmitted to the concrete slab. As a result, the amount of vibration and sound energy applied to the ceiling finishing material on the lower floor is greatly reduced.

[0199] Furthermore, the present invention proposes several buffer structures that can mitigate impact when connecting the lightweight structural material 100 and the wall, thereby more effectively blocking the transmission of noise from the lightweight structural material 100 through the wall, and thereby maximizing the effect of reducing inter-story noise.

[0200] The following describes a connecting structure that can be applied between the lightweight structural material 100 and a wall according to the present invention, with reference to Figures 19 to 22.

[0201] First, let's look at the first wall connection structure, referring to Figure 19. In the first wall connection structure, anchor pads 211 are installed on the building wall, and metal plates 212 are welded to both ends of the lightweight structural member 100 along its longitudinal direction for fastening to the anchor pads 211. The anchor pads 211 and the metal plates 212 are fixed and connected to each other through bolted connections, and at this time, a vibration-reducing cushioning material can be placed between the anchor pads 211 and the metal plates 212 to mitigate the impact transmitted from the lightweight structural member 100 to the wall.

[0202] Next, referring to Figure 20, we will examine the second wall connection structure. In the second wall connection structure, the lower part of the anchor pad 221 installed on the building wall is provided in the form of an L-shaped angle (or an L-shaped angle member is connected to the lower end of the anchor pad 221), and the lower end of the metal plate 222 is inserted into the space formed by the lower L-shaped angle of the anchor pad 221, and is supported while preventing detachment in the horizontal direction.

[0203] The upper end of the metal plate 222 can be fixed to the anchor pad 221 or the wall through a bolted connection.

[0204] Furthermore, vibration-reducing cushioning material or springs can be additionally placed between the metal plate 222 and the anchor pad 221 in order to mitigate the impact transmitted from the lightweight structural material 100 to the wall.

[0205] The second wall connection structure is a system in which the lower end of the metal plate 222 is housed and supported by a separate member, simply inserted into the space without mechanical fastening, and only the upper end is fastened by bolting. Since the metal plate 222 is placed on an anchor pad 221 including an L-shaped angle and only the upper end is fixed to the wall side, it is possible to achieve a connection that is very easy to work with on site and is structurally robust.

[0206] Next, referring to Figure 21, we will examine the third wall connection structure. In the third wall connection structure, the anchor pad 231 installed on the wall of the building and the metal plate 232 welded to the edge along the longitudinal direction of the lightweight structural material 100 are connected in a hinge manner, and the metal plate 232 is configured to be rotatable with respect to the hinge axis, and an elastic spring 233 is placed between the anchor pad 231 and the metal plate 232 to mitigate the impact transmitted from the lightweight structural material 100 to the wall.

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

[0208] If the second wall connection structure shown in Figure 20 is a structure that does not restrain the lower end of the metal plate 222 and allows slight movement within a predetermined range, then the third wall connection structure shown in Figure 21 can be understood as a structure that restrains 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 Figure 22 is a method of connecting the lightweight structural material 100 to the building wall via a vibration reduction device 241, rather than 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, vibrations caused by impacts generated in the lightweight structural material 100 are not transmitted to the wall. Furthermore, since vibrations transmitted from the lightweight structural material 100 to the concrete slab can be absorbed by the vibration reduction device 241, impacts transmitted in the vertical direction can also be effectively mitigated.

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

[0212] B. Building ceiling structure

[0213] Although not shown in the illustrations, the lightweight structural material 100 according to the present invention can also be installed beneath a concrete slab and used as the ceiling structure of the lower floor.

[0214] In this case, the ceiling finishing material of the lower floor can be directly attached to the underside of the lightweight structural material 100, eliminating the need for separate support base construction and woodworking for attaching the ceiling finishing material, thus simplifying the ceiling construction.

[0215] Furthermore, since various types of piping and concealed piping (for example, ceiling-mounted air conditioners) to be installed in the ceiling can be easily attached to the lightweight structural material 100 according to the present invention, it becomes possible to apply a modular construction method via pre-installed piping.

[0216] C. Utilized as a superimposed structure

[0217] As shown in Figure 23, the lightweight structural material 100 according to the present invention can also be used by arranging them in a stacked configuration.

[0218] When two lightweight structural members 100 are stacked in this manner, the advantage is that various concealed pipes can be pre-installed in the space between the upper and lower lightweight structural members 100, making it easy to add a variety of additional functions.

[0219] As an example, referring to Figure 24, an ondol (Korean underfloor heating) function can be easily added by installing insulation material (I) and heating / cooling pipes (P) in the space between lightweight structural materials 100 arranged in a vertical superposition. Here, the insulation material (I) can be placed only below the heating / cooling pipes (P) so that the cooling or heating from the thermal fluid flowing through the heating / cooling pipes (P) is efficiently transferred upwards, and the area around the heating / cooling pipes (P) can be left as an open space.

[0220] Typically, the mortar finishing work for an ondol (Korean underfloor heating) floor involves laying insulation on a concrete slab, installing hot water pipes on top of that, and then applying the finishing mortar. In this process, to achieve a uniform level of flatness during mortar application, it is necessary to use mortar with a high water content, which means it takes a long time to harden and creates many inconveniences in the work.

[0221] However, when applying the present invention, the lightweight structural material 100 placed on top performs a structural function, eliminating the need for separate mortar work. Therefore, an ondol structure and / or floor heating and cooling structure can be constructed very conveniently and easily.

[0222] Furthermore, as shown in Figure 25, by adding a fire-resistant material (R) between the lightweight structural material 100 and the insulation material (I) located at the bottom, it is possible to achieve fire resistance for the floor without separate fire-resistant coating.

[0223] According to domestic and international floor fire resistance standards, while the ability of the unheated surface of structural materials to rise in temperature is important, equally important and under consideration is the structural stability against fire. More specifically, a load exceeding a certain weight (e.g., 3kN / m) on top of the structural material is considered important. 2 With the heat source in place, the lower part of the structural material is exposed to the heat source, and after a certain period of time (for example, 2 hours), the amount of deflection of the structure is checked to evaluate its structural stability.

[0224] In the case of conventional building structural materials made of metal, when exposed to heat during fire resistance testing, they lose their structural performance when the temperature exceeds a certain level. Therefore, additional work is carried out to coat the underside of the metal with fire-resistant material in order to meet fire resistance standards.

[0225] However, as shown in Figure 25, if the fire-resistant material (R) is placed in advance inside the superimposed structure formed by the superimposed arrangement of lightweight structural materials 100, even if the lightweight structural materials 100 placed at the bottom are exposed to the heat source due to a fire and lose their structural performance, the upper lightweight structural materials 100 protected by the fire-resistant material (R) will maintain their structural performance. Therefore, structural stability can be maintained in a fire situation without the need for additional fire-resistant coating work as in the past, and the aforementioned fire resistance standards can be easily met.

[0226] When arranging the lightweight structural members 100 according to the present invention in a superimposed configuration, if an additional function is to be added to the space between them, or if the structure itself incorporates a double-floor structure to double the inter-story noise reduction effect, the lightweight structural members 100 facing each other vertically can be arranged at a predetermined distance apart. Furthermore, since each lightweight structural member 100 constituting the superimposed structure can be individually fixed within the structure, the lightweight structural members 100 arranged vertically do not necessarily need to be directly structurally connected.

[0227] When the lightweight structural material 100 according to the present invention is arranged in a double layer and used as a floor structure for a building, the impact sound that is the direct cause of inter-story noise is generated by the lightweight structural material 100 placed on top. Therefore, the upper lightweight structural material 100 is connected to the building wall in a way that allows for buffering by applying the first to fourth wall connection structures described above, and the lower lightweight structural material 100 can be connected to the wall through simple mechanical fastening such as bolt fastening.

[0228] When the lightweight structural material 100 according to the present invention is used as a structural material for a building, the following effects and benefits can be expected.

[0229] First, it becomes possible to realize ultra-lightweight, long-span dry structures with far superior structural performance, and when used, the overall efficiency of construction work can be greatly increased.

[0230] During construction, reinforced concrete floor construction is the most complex and time-consuming basic structural work of the entire project. In particular, it is heavily influenced by environmental factors and is often constructed using a wet method under unfavorable site conditions, making it one of the most crucial aspects of construction management and performance realization. Recently, there have been cases where rushing into wet concrete slab construction to shorten the construction period has led to serious accidents.

[0231] The lightweight structural material 100 presented in this invention weighs only about 30-40% of concrete, but it enables the realization of long-span structures far longer than conventional reinforced concrete floor structures. Moreover, because it is constructed using a dry method, it is hardly affected by environmental factors, offering the advantage of dramatically reducing complicated and cumbersome on-site construction processes. Furthermore, unlike wet construction methods, its structural performance is realized immediately upon installation, significantly shortening the overall construction period.

[0232] Furthermore, by using the lightweight structural material 100 according to the present invention, it is possible to realize a robust double-floor structure that does not require a support base, and thus, the problem of inter-floor noise, which is a major social issue, can be reduced in a groundbreaking manner.

[0233] Furthermore, when the lightweight structural material 100 according to the present invention is used as a floor structure for a building, the ondol floor mortar finishing work can be simplified. As seen above, the lightweight structural material 100 according to the present invention has far superior structural performance, so there is no need to perform ondol construction (heating work) on the lightweight floor in order to increase structural strength, as is the case with conventional double-floor structures. Therefore, when the lightweight structural material 100 according to the present invention is installed on a conventional concrete slab, the hot water piping and heating / cooling piping work required for ondol construction can be conveniently performed on the conventional concrete, and there is no need to perform separate mortar work for floor mortar finishing, which is an advantage.

[0234] Conventional ondol floor mortar finishing work involves installing insulation on a concrete slab and then placing hot water pipes. To create a flat, walkable floor, floor mortar work or the additional installation of separate dry ondol panels was required before the finishing floor material could be applied. However, the lightweight structural material 100 according to the present invention functions as a sufficient structural material on its own, eliminating the need for the separate floor mortar work or dry ondol panel installation work that was previously performed. As a result, the finishing floor material can be applied immediately on top of the lightweight structural material 100, making ondol floor mortar finishing work far simpler.

[0235] The construction of steps can also be simplified. Typically, toilet and entrance floors are designed to have a step that is several tens of millimeters (mm) lower than other floor slabs. Conventional construction methods required formwork and floor mortar finishing to create such steps. However, according to the present invention, all floor slabs on the same floor can be manufactured flat, and the step only needs to be constructed on the lightweight structural material 100. This simplifies the construction of steps and makes it very convenient to manufacture step structures for toilet and entrance floor slabs.

[0236] Furthermore, when the lightweight structural material 100 according to the present invention is used as the ceiling structure of a building, the ceiling finishing material of the floor below can be directly attached to the underside of the lightweight structural material 100, thereby simplifying ceiling construction. It also enables the application of a modular construction method through pre-installation of various pipes and concealed pipes to be installed in the ceiling to the lightweight structural material 100.

[0237] Furthermore, when the lightweight structural material 100 according to the present invention is arranged in a superimposed configuration, it has the advantage that various pipes, ceiling fixtures, and other components can be pre-installed inside or below the structure.

[0238] For example, by easily installing the necessary insulation material (I) and heating / cooling pipes (P) for the floor ondol as pre-installed piping within the structure (see Figure 24), the separate ondol floor mortar finishing work can be omitted, thus greatly simplifying the overall construction process. Furthermore, the floor temperature can respond more quickly to temperature adjustments, and the structure for raising the temperature is much lighter and simpler, resulting in a significant advantage in terms of thermal efficiency. In addition, by placing fire-resistant material (R) as pre-installed piping within the structure (see Figure 25), it is possible to fully realize fire resistance performance without the need for a separate subsequent fire-resistant process.

[0239] The present invention is not limited to the embodiments described, and it will be obvious to those ordinary skill in the art that it can be modified and transformed in various ways without departing from the spirit and scope of the invention. Accordingly, such modifications or variations can be said to fall within the scope of the claims of the present invention. This disclosure also includes the following aspects: [Aspect 1] A first main plate made of metal, A plurality of reinforcing plates made of metal material are arranged on one side of the first main plate at a predetermined distance apart, including a first reinforcing plate formed in a direction parallel to the first main plate and a second reinforcing plate bent to one side from the first reinforcing plate, and The system includes a core layer made of a non-metallic material formed in the space between the first main plate and the reinforcing plate, and in the space between adjacent reinforcing plates. The protruding structure determined by the adjacent second reinforcing plates and the core layer formed between them functions as a plate reinforcing material. A lightweight structural material with integrated plate reinforcement based on composite materials. [Aspect 2] The aforementioned protruding structures are formed at predetermined intervals along the width direction of the lightweight structural material and are extended along the longitudinal direction while maintaining a constant cross-sectional shape. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 3] The core layer is characterized by being formed of a non-foaming polymer. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 4] The first reinforcing plate and the second reinforcing plate are provided integrally. The second reinforcing plate is characterized by being formed by bending the first reinforcing plate. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 5] The edge of the protruding structure is bent again, or a separate finishing material is attached to the edge of the protruding structure. The vertical reinforcing portion formed perpendicular to the protruding structure forms the web of the plate reinforcing material, and the vertical reinforcing portion formed horizontally from the protruding structure forms the flange of the plate reinforcing material. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 6] Of the aforementioned plurality of reinforcing plates, the remaining reinforcing plates, excluding those positioned at both edges along the width direction, have a cross-section with closed sides on all four sides. The system further includes a second main plate, which is arranged on one side of the reinforcing plate at a predetermined distance apart. The core layer is further formed between the reinforcing plate and the second main plate. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 7] The core layer is further characterized by the placement of a high-performance thermal insulation material having a thermal conductivity of 0.02 W / mK or less. A lightweight structural material with integrated plate reinforcement based on a composite material, as described in Embodiment 3. [Aspect 8] The aforementioned high-performance insulation material is characterized by being a vacuum insulation panel (VIP). A lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 7. [Aspect 9] The side edge finishing material further includes a material for finishing the frame portion between the first main plate and the reinforcing plate. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in Embodiment 1. [Aspect 10] The side edge finishing material is inserted between the first main plate and the reinforcing plate, but is characterized by being pushed in by a predetermined distance from the edges of the first main plate and the reinforcing plate. A lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 9. [Aspect 11] When connecting adjacent lightweight structural members, the first main plates facing each other and the reinforcing plates facing each other are joined by welding, and a non-foaming polymer concentrate is injected into the space formed between the first main plate, the reinforcing plate and the side edge finishing material and cured, thereby ensuring a tightly sealed joint. A lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 10. [Aspect 12] The side edge finishing material is provided in an angle shape having a straight or bent structure, with one end inserted between the first main plate and the reinforcing plate, and the other end protruding to the outside of the first main plate and the reinforcing plate. A lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 9. [Aspect 13] When connecting adjacent lightweight structural members, the side end finishing members facing each other are structurally joined by welding or bolting, A lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 12. [Aspect 14] A method for manufacturing a lightweight structural material comprising a main plate made of metal, a plurality of reinforcing plates made of metal, including a first reinforcing plate formed in a direction parallel to the main plate and a second reinforcing plate bent to one side from the first reinforcing plate, which are arranged at a predetermined distance from the main plate, and a core layer formed in the space between the main plate and the reinforcing plates and in the space between adjacent reinforcing plates, The steps include filling the space between the main plate and the reinforcing plate and the space between adjacent reinforcing plates with a non-foaming polymer stock solution, The steps include curing the non-foaming polymer stock solution and This includes the step of curing the non-foaming polymer stock solution and completing the formation of the core layer. A method for manufacturing lightweight structural materials with integrated plate reinforcement based on composite materials. [Aspect 15] In the step of filling the non-foaming polymer stock, a space is formed behind the main plate, and after pouring the non-foaming polymer stock, the plurality of reinforcing plates are inserted and pressurized to a position where there is a predetermined distance between them and the main plate. The pressurizing force of the reinforcing plates causes the non-foaming polymer stock to overcome the frictional resistance due to viscosity and dissolve into the space between the plurality of reinforcing plates, filling it evenly. A method for manufacturing a lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 14. [Aspect 16] The amount of the non-foaming polymer concentrate initially poured into the space formed on the back of the main plate is at least 2% more than the actual volume occupied by the core layer, and the excess is pushed out and discharged by the pressurizing force of the reinforcing plate. A method for manufacturing a lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 15. [Aspect 17] In the step of filling the non-foaming polymer stock solution, the space in which the core layer is formed is sealed, and the non-foaming polymer stock solution is injected into the sealed space using an injection tube, characterized in that the injection tube is divided into several small tubes and arranged within the sealed space. A method for manufacturing a lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 14. [Aspect 18] In the step of filling the non-foaming polymer stock solution, the space in which the core layer is formed is sealed, an injection tube is inserted into one side of the sealed space, and while the non-foaming polymer stock solution is injected, air is sucked out of the sealed space on the other side using a vacuum pump. A method for manufacturing a lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 14. [Aspect 19] In at least one of the steps of filling the non-foaming polymer stock solution and curing the non-foaming polymer stock solution, a magnet is placed on at least one surface of the main plate and the reinforcing plate, or it is attracted by a vacuum adsorption device and a tensile force is applied, for the purpose of maintaining flatness. A method for manufacturing a lightweight structural material with a composite material base and integrated plate reinforcement, as described in Embodiment 14.

Claims

1. A first main plate made of metal, A plurality of reinforcing plates made of metal material are arranged on one side of the first main plate at predetermined intervals, including a first reinforcing plate formed in a direction parallel to the first main plate and a second reinforcing plate bent from the first reinforcing plate in a direction perpendicular to the first main plate, and The system includes a core layer made of a non-metallic material formed in the space between the first main plate and the reinforcing plate, and in the space between adjacent reinforcing plates. The protruding structure determined by the adjacent second reinforcing plates and the core layer formed between them functions as a plate reinforcing material. The core layer is formed of a non-foaming polymer. A lightweight structural material with integrated plate reinforcement based on composite materials.

2. The aforementioned protruding structure is formed at predetermined intervals along the width direction of the composite material-based plate-reinforced lightweight structural material, and is extended along the longitudinal direction while maintaining a constant cross-sectional shape. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in claim 1.

3. The first reinforcing plate and the second reinforcing plate are provided integrally. The second reinforcing plate is characterized by being formed by bending the first reinforcing plate. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in claim 1.

4. The edge of the protruding structure is bent again, or a separate finishing material is attached to the edge of the protruding structure. The vertical reinforcing portion formed perpendicular to the protruding structure forms the web of the plate reinforcing material, and the vertical reinforcing portion formed horizontally from the protruding structure forms the flange of the plate reinforcing material. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in claim 1.

5. The core layer is further characterized by the placement of a high-performance thermal insulation material having a thermal conductivity of 0.02 W / mK or less. A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in claim 3.

6. The aforementioned high-performance thermal insulation material is characterized by being a vacuum thermal insulation material (VIP). A lightweight structural material with an integrated plate reinforcement based on a composite material, as described in claim 5.

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