Modular construction of prefabricated panels, method for manufacturing said panels and mould for carrying out said method

Abstract

The present invention relates to a modular construction of prefabricated panels, to a method for manufacturing said panels and to a mould for carrying out said method, the panels being formed by sandwich boards with an inner layer (5), an outer layer (6) and an insulation core (7), wherein said boards comprise, incorporated between their layers, a metal structure of pillars (8) in wall panels (2, 3) and beams (9) in formwork panels (4), which are welded to each other. The method comprises placing, in a mould (20), the inner layer (5) or outer layer (6), the pillars (8) or beams (9), the layer (6) or (5) of the opposite side, and once the cover (22) is closed, injecting foam material of the core (7), sealing the mould for 35-40 minutes and demoulding the resulting part. The mould (20) comprises a lifting mechanism (25) for lifting the sides (21.1) of the lower body (21) in order to place it flush with the bottom (21.2).

Description

[0001] DESCRIPTION

[0002] MODULAR CONSTRUCTION OF PREFABRICATED PANELS, MANUFACTURING PROCESS OF SAID PANELS AND MOULD TO CARRY OUT SAID PROCESS

[0003] OBJECT OF THE INVENTION

[0004] The invention, as expressed in the statement of this specification, refers to a modular construction of prefabricated panels, to a manufacturing process of said panels and to a mold to carry out said process, which provide advantages and characteristics, which are described in detail below.

[0005] The object of the present invention lies in a modular construction of those formed based on prefabricated panels, which are distinguished, essentially, by being formed from lightweight sandwich-type plates, comprising an interior and an exterior finishing layer between an intermediate thermal / acoustic insulation layer, and which also include a structure of metal profiles incorporated that are welded together acting as pillars and beams to form the walls and floors of the construction, providing a construction system that is lightweight, easy to transport and very quick to assemble. Also object of the present invention is a manufacturing process for said panels, as well as a specific mold to carry out said process.

[0006] FIELD OF APPLICATION OF THE INVENTION

[0007] The field of application of the present invention falls within the construction sector, focusing particularly on the field of construction of modular buildings from prefabricated elements.

[0008] BACKGROUND OF THE INVENTION

[0009] Typically, the walls and floors of buildings are made of brick or concrete. They can also be made of sandwich panels, formed by joining several layers of different materials, allowing for the creation of prefabricated elements that speed up construction. The problem is that the sandwich panels currently available require the prior installation of a metal structure, which is used to support the upper floor.

[0010] The objective of the present invention is the development of an improved construction system based on prefabricated panels that, among other advantages, avoid the need for the creation and installation of the metal support structure, allowing for a much greater reduction in assembly times.

[0011] On the other hand, and as a reference to the current state of the art, it should be noted that, although other types of constructions based on prefabricated panels are known, at least by the applicant, the existence of any that presents technical, structural and constitutive characteristics equal to or similar to those claimed here is unknown.

[0012] EXPLANATION OF THE INVENTION

[0013] The modular construction of prefabricated panels that the invention proposes is configured as an ideal solution to the objectives previously indicated which, in turn, represents an improvement of the current state of the art, the characterizing details that make it possible and that distinguish it being conveniently included in the final claims that accompany this description.

[0014] Specifically, what the invention proposes, as previously indicated, is a modular construction formed from prefabricated panels, which are advantageously formed from lightweight sandwich-type plates, which, at least, comprise an interior finishing layer and an exterior finishing layer between which there is a core or an intermediate and light layer of thermal and acoustic insulation material, and which, in addition, include, incorporated between said layers, a structure of metal profiles, L-shaped or in the form of IPN or IPE, which are welded together acting respectively as pillars and as beams to form the walls and the floors of the construction, providing a construction system that is light and easy to transport and very quick to assemble.

[0015] Furthermore, thanks to the material's lightness, its transport is much more efficient, as a trailer-type truck can transport a home of about 120 m2.

[0016] In any case, in addition to the fact that assembly, thanks to the panels' lightness, is much faster than in conventional construction, since the prefabricated panels are custom-made pieces for each solution, no waste is generated.

[0017] Preferably, the insulating material layer of the panels is high-density rigid polyurethane foam and the external and internal layers, depending on whether the panels define the façade walls, partition walls or floors, can be made of different materials, preferably high-density fiber-reinforced cement, which has high mechanical and impact resistance, excellent fire behavior and high thermal and acoustic insulation values, but without ruling out the use of other materials, especially on the internal face in the case of façade walls and on both sides in the case of partition walls, such as fiber cement, wood, plasterboard, or laminated plaster or pladur ®.

[0018] Furthermore, wall and floor panels can be made up of slabs with varying thickness, length, height, and width. However, all slabs should preferably be 70 to 300 mm thick, preferably 150, 200, or 250 mm, etc., and come in various lengths between 1 and 10 meters, as appropriate, as well as varying widths between 30 and 240 cm. However, wall panel slabs are preferably manufactured 1200 mm wide by 3000 or 3150 mm high, while slabs are 1200 mm wide by 200 or 250 mm thick and come in various lengths.

[0019] In any case, all panels have an integrated metal structure capable of supporting the home's loads and are also manufactured with the corresponding electrical, water, drainage, and even heating systems. Furthermore, wall panel panels are preferably finished on the inside with a layer of fiber plaster, laminated plaster, wood, fiber cement, or ceramic, and on the outside with a layer of high-density fiber-reinforced cement, where the façade will be attached.

[0020] Thus, the configuration, specific material size and internal pre-installations of each of the sandwich panels that make up the panels can vary and will depend on whether they are intended to be used as a façade panel, a slab panel, a radiant panel or a partition panel.

[0021] With all this, each of the building's panels constitutes a very light plate, making assembly much faster. Preferably, for this assembly, the walls are joined with an L-shaped metal angle, preferably made of iron, which includes the pieces that make up the wall panels vertically on the inside of each side. A horizontal angle is placed at the bottom and top of the walls, so that they will be joined by welding. Furthermore, this upper horizontal angle, in turn, serves as a support for the plates that make up the slab panels, which will be welded to the internal metal structure of the slabs of these slab panels, based on IPN profiles, creating a very rigid structure between the walls and the slabs.

[0022] The manufacturing process of the plates, which is carried out in a specific mould, essentially comprises the following:

[0023] - The process begins by raising the upper gate of the mold, which will have the appropriate dimensions, according to the project.

[0024] - Next, one of the panel's covering layers, preferably the outer one, is placed on the bottom of the mold.

[0025] - Next, the metal profiles that make up the pillars or beams are installed. Specifically, the L-shaped profiles are placed in the corners of the lower part of the mold, on top of the covering layer, in the case of the pillars for the wall panels, and, in the case of the floor panels, the corresponding IPN or IPE beams are placed.

[0026] - Next, the appropriate electrical, plumbing, or heating pipes are added. Preferably, these pipes are installed so that two pipes are placed transversely, approximately 30 cm from the bottom and top of the mold, and three pipes are placed longitudinally, two approximately 10 cm from each side and one centered in the mold.

[0027] - Next, the coating layer is placed on top of the mold, with the corresponding measurements according to the project.

[0028] - Then, the mold's top hatch or lid, which is preferably hydraulic, is closed. - Once the mold is closed, the foam that will form the insulation core is injected, preferably through a hole centered on the side or top of the mold, for optimal foam distribution.

[0029] - Optionally, after completing the foam injection, the injector is optionally removed and the mold is sealed for, for example, 35 - 40 minutes.

[0030] - After the setting time has elapsed, the upper gate of the mold is lifted by activating a button that activates the pistons that move and lift the lid, lifting the lid.

[0031] - Finally, the resulting piece is removed from the mold, preferably using a pusher.

[0032] Finally, the mould used to carry out said process comprises a lower fixed body, with an upper tilting lid, which, among other advantages, has side walls of said body that are movable with respect to the bottom in order to lower them and leave them flush, in such a way that the piece can be pushed by dragging it over it, preferably with the help of a pusher provided for this purpose.

[0033] DESCRIPTION OF THE DRAWINGS

[0034] To complement the description being made and in order to help better understand the characteristics of the invention, a drawing is attached to this specification, as an integral part thereof, in which the following has been represented for illustrative and non-limiting purposes:

[0035] Figures 1-A and 1-B show schematic views, in cross-section and front elevation respectively, of an example of a board comprising the modular structure object of the invention as a lower wall panel, showing the parts and elements it comprises, as well as their configuration and arrangement; Figures 2-A and 2-B show schematic views, in cross-section and front elevation respectively, of another example of a board comprising the modular structure of the invention as an upper wall panel, showing the parts and elements it comprises, as well as their configuration and arrangement; Figures 3-A and 3-B.- They show schematic views, in cross-section and front elevation respectively, of another example of a plate comprising the modular structure of the invention as a forged panel, showing the parts and elements it comprises, as well as their configuration and arrangement; Figure 4.- Shows a schematic side elevation view of an example of the assembly of some of the panels shown in the preceding figures to form the construction; and Figure 5.- Shows a schematic perspective view of an example of the mold used to carry out the manufacturing process of the plates that make up the panels of the modular construction of the invention.

[0036] PREFERRED EMBODIMENT OF THE INVENTION

[0037] In view of the aforementioned figures, and in accordance with the adopted numbering, one can observe in them a non-limiting embodiment of the modular construction of prefabricated panels of the invention, which comprises what is described in detail below.

[0038] Thus, as can be seen in figures 1-A to 4, the construction (1) object of the invention essentially comprises a plurality of prefabricated panels (2,3,4), formed by sandwich type plates with at least one inner layer (5) and an outer layer (6) between which there is a light core (7) of thermal and acoustic insulation, with the particularity that they also comprise, incorporated between said layers, a metal structure of profiles which, respectively defining pillars (8) in vertical wall panels (2,3) and beams (9) in horizontal forging panels (4), are welded together, said profile structure being suitable for supporting the loads of the construction (1) assembled as a building such as a house or similar with one or more floors.

[0039] Preferably, the plates defining the wall panels (2, 3) comprise, as pillars (8) of the metal support structure, at least two metal profiles in an angle or L-shaped section, incorporated longitudinally on both sides of the plate, between the core (7) and the inner layer (5). And, preferably, the plates defining the floors (4) comprise, as beams (9) of the metal support structure, one or more metal profiles with an IPN or IPE-shaped section incorporated longitudinally between the core (7) and the inner layer (5).

[0040] Preferably, the metal profiles that make up the pillars (8) and beams (9) are made of steel.

[0041] Preferably, to facilitate welding between the profiles that define the pillars (8) of the wall panels (2, 3) and the beams (9) of the forging panels (4), the inner layer (5), at least in the plates of the wall panels (2, 3), has lower uncovered sections (10) and upper uncovered sections (11) in which a portion of said profiles of the pillars (8) are exposed, such that another profile can be welded to them.

[0042] Furthermore, in a preferred embodiment, the construction comprises the inclusion of additional joining profiles (12) which, formed by angles arranged in a horizontal position, are placed on the lower and upper part of the wall panels (2, 3) walls in coincidence with the aforementioned uncovered sections (10, 11) of their inner face, so that they will be joined by welding to the profiles that define the pillars (8).

[0043] Furthermore, the additional upper joining profile (12) in turn serves as a support to hold the plates that make up the panels of the slab (4), as can be seen in Figure 4.

[0044] In one embodiment, the construction comprises lower wall panels (2), such as those shown in Figures 1-A and 1-B, intended to form the wall enclosures of a lower floor of the construction (1) when it has several floors, and upper wall panels (3), such as those shown in Figures 2-A and 2-B, intended to form the enclosures of the upper floor of the construction, under an upper roof.

[0045] Preferably, in the lower wall panels (2), the lower (10) and upper (11) exposed sections of the inner layer (5) are located respectively at the lower and upper ends or edges of the plate. And, in the upper wall panels (3), while the lower exposed section (10) is located at the lower end or edge of the plate, the upper exposed section (11) is located at a certain distance from the upper end or edge of the plate. For their part, the slab panels (4) will serve both to form the floor of the ground floor and the ceiling and floor of the other floors.

[0046] Furthermore, preferably, both the wall panels (2, 3) and the forging panels (4) have, on the side edges, recesses (13) and protrusions (14) that fit together in a tongue-and-groove manner to join the plates coplanarly.

[0047] Preferably, the lightweight thermal and acoustic insulation core (7) of all panels (2, 3, 4) is made of rigid polyurethane foam (PIR or PUR), formed in a heated pressure mould, as described in the manufacturing process of the panels, with high density (>40kg / m3) and closed cells, with low thermal conductivity.

[0048] Preferably, the inner layer (5) and / or the outer layer (6) of the wall panels (2, 3) or slab (4) is a high-density fiber-reinforced cement board (HYDROPANEL or similar), with high mechanical and impact resistance, which has excellent fire performance and high thermal and acoustic insulation values.

[0049] However, optionally, the inner layer (5) and / or the outer layer (6), especially in the case of wall panels (2, 3), may be made of fiber cement, wood, plasterboard, PLADIIR type plaster or similar, or others.

[0050] Finally, it should be noted that the wall panels (2, 3) are preferably manufactured with the corresponding installations of electricity, water, drainage or radiant heating system incorporated.

[0051] Thus, preferably, the wall panels (2, 3) intended to serve as façade or partition panels, include, as electrical pre-installations, pipes for wiring, arranged horizontally and vertically, located according to the project needs, and as water pre-installations, pipes for sanitary water, horizontally and / or vertically, according to needs. And the wall panels (2, 3) intended to serve as radiant panels, include, as heating pre-installations, an electrical wiring coil or coil with a water pipe, for heating, integrated into the panel.

[0052] Finally, looking at Figure 5, a schematic representation of the mould (20) is observed, with which the manufacturing process of the described panels (2, 3, 4) of the invention is carried out, which comprises the following essential elements:

[0053] A long, fixed lower body (21) that supports a tilting upper cover (22), which can be completely folded down to a vertical position, so that the piece can be removed, once obtained, by dragging it laterally, for which purpose a crane with a hook (23) or similar can be used.

[0054] Preferably, said cover (22) is hydraulically actuated by means of pneumatic pistons (24).

[0055] The lid (22) is preferably divided into two halves (a), to be able to make two independent short pieces or one long one.

[0056] In any case, the mould (20) also comprises a lifting mechanism (25), for example a hydraulic scissor lift, which raises and lowers at least one of the side edges (21.1) of the lower body (21) of the mould, to place it flush with the bottom (21.2) and allow the piece to be dragged laterally once finished, sliding it over said bottom (21.2) of said lower body.

[0057] (21).

[0058] And, preferably, the existence is provided, on the opposite side of the fixed long lower body (21), of a pushing mechanism (26), which collaborates in the extraction operation of the piece to be able to drag it laterally after having lowered the sides of the lower body (21).

[0059] In any case, the manufacturing process of the plates that make up the described panels (2, 3, 4), and which is carried out in said mould (20), essentially comprises the following:

[0060] - The process begins by raising the upper cover (22) of the mold (20), which will have the appropriate dimensions, according to the project.

[0061] - The inner layer (5) or the outer layer (6) of the plate to be obtained is placed at the bottom of the lower body (21) of the mold (20), as appropriate.

[0062] - The metal profiles of pillars (8) are placed when the plate is a wall panel (2, 3) or of beams (9) when the plate to be obtained is a forged panel (4). - The pre-installation electrical, water or heating pipes are incorporated.

[0063] - The covering layer (6, 5) is placed on the opposite side of the panel to the one previously placed.

[0064] - The lid (22) of the mold (20) is closed.

[0065] - Once the mould (20) is closed, the foam material that will form the intermediate insulation core (7) is injected using an injector (30) through, preferably, a hole (27) provided in the centre of the side or upper part of the lower body (21) of the mould (20).

[0066] - Optionally, after completing the foam injection, the injector (30) is removed and the hole (26) is closed, leaving the mold sealed, for example for 35 - 40 minutes, so that the foam sets and becomes rigid.

[0067] - After the setting time, the upper lid (22) of the mold is lifted by activating a button that activates the pistons (24) that move and lift the lid.

[0068] - Finally, the resulting piece is removed from the mold.

[0069] Having sufficiently described the nature of the present invention, as well as the manner of putting it into practice, it is not considered necessary to make its explanation more extensive so that any expert in the field understands its scope and the advantages derived from it.

Claims

CLAIMS 1.- Modular construction of prefabricated panels comprising a plurality of prefabricated panels, formed by sandwich type plates with at least an inner layer (5) and an outer layer (6) between which there is a light core (7) of thermal and acoustic insulation, is characterized by the fact that said plates also comprise, incorporated between their layers, a metal structure of profiles that define, respectively, pillars (8) in vertical wall panels (2, 3) and beams (9) in horizontal forging panels (4), which are welded together, said profile structure being suitable to support the loads of the construction (1) assembled as a building such as a house or similar with one or more floors. 2.- Modular construction of prefabricated panels, according to claim 1, characterized in that the plates that define the wall panels (2, 3) comprise, as pillars (8) of the metal support structure, at least two metal profiles in angle or L-shaped section, incorporated longitudinally on both sides of the plate, between the core (7) and the inner layer (5). 3.- Modular construction of prefabricated panels, according to claim 1 or 2, characterized in that the plates that define the floors (4) comprise, as beams (9) of the metal support structure, one or more metal profiles with a section in the form of IPN or IPE incorporated longitudinally between the core (7) and the inner layer (5). 4.- Modular construction of prefabricated panels, according to any of the previous claims, characterized in that the inner layer (5), at least in the plates of the wall panels (2, 3), has lower uncovered sections (10) and upper uncovered sections (11) in which a portion of said profiles of the pillars (8) are exposed, such that another profile can be welded to them. 5.- Modular construction of prefabricated panels, according to claim 4, characterized in that it comprises the inclusion of additional joining profiles (12) which, formed by angles arranged in a horizontal position, are placed on the lower and upper part of the wall panels (2, 3) walls in coincidence with the aforementioned uncovered sections (10, 11) of their inner face. 6.- Modular construction of prefabricated panels, according to claim 5, characterized in that the additional upper joining profile (12) serves as a support to support the plates that make up the panels of the slab (4). 7.- Modular construction of prefabricated panels, according to any of claims 4 to 6, characterized in that it comprises lower wall panels (2), intended to form the wall enclosures of a lower floor of the construction (1), and upper wall panels (3), intended to form the enclosures of the upper floor of the construction, under an upper roof. 8.- Modular construction of prefabricated panels, according to claim 7, characterized in that, in the lower wall panels (2), the lower (10) and upper (11) uncovered sections of the inner layer (5) are located respectively at the lower and upper ends or edges of the plate; and, in the upper wall panels (3), the lower uncovered section (10) is located at the lower end or edge of the plate and the upper uncovered section (11) is located at a certain distance from the upper edge or end of the plate. 9.- Modular construction of prefabricated panels, according to any of the preceding claims, characterized in that the lightweight thermal and acoustic insulation core (7) of all the panels (2, 3, 4) is made of rigid polyurethane foam. 10.- Modular construction of prefabricated panels, according to any of the preceding claims, characterized in that the inner layer (5) and / or the outer layer (6) of the wall panels (2, 3) or forging (4) is a cement board reinforced with high-density fibers. 11.- Modular construction of prefabricated panels, according to any of claims 1 to 9, characterized in that the inner layer (5) and / or the outer layer (6), especially in the case of wall panels (2, 3) is made of fiber cement, wood, plasterboard, or PLADIIR type plaster or similar. 12.- Process for manufacturing panels, for a construction of prefabricated wall panels (2, 3) or forging (4), as described in any of claims 1 to 11, characterized in that it comprises the following: - the process begins by raising the upper cover (22) of a mold (20), with the dimensions as appropriate, according to the project; - the inner layer (5) or the outer layer (6) of the plate to be obtained is placed at the bottom of the lower body (21) of the mold (20); - metal profiles of pillars (8) are placed when the plate is a wall panel (2, 3) or beams (9) when the plate to be obtained is a forged panel (4); - pre-installation pipes for electrical, water or heating are incorporated, if applicable; - the covering layer of the outer layer (6) or inner layer (5) is placed on the opposite side of the panel to the one placed previously; - the lid (22) of the mold (20) is closed; - by means of an injector (30), the foam material that forms the intermediate insulation core (7) is injected through a hole (27) provided in the mold (20); - optionally the injector (30) is removed and the hole (26) is closed, leaving the mold sealed; - after the setting time, the upper cover (22) of the mold (20) is lifted; - the resulting piece is removed from the mold. 13.- Mold to carry out a panel manufacturing process, as described in claim 12, characterized in that it comprises a long, fixed lower body (21), which supports an upper tilting cover (22), which can be completely folded down to a vertical position, and because it also comprises a lifting mechanism (25) that raises and lowers at least one of the side edges (21.1) of the lower body (21) of the mold, to place it flush with the bottom (21.2) and allow the lateral drag of the piece by sliding it on said bottom (21.2) of said lower body (21). 14.- Mold, according to claim 13, characterized in that the existence of a pushing mechanism (26) is provided, which collaborates in the extraction operation of the piece to be able to drag it laterally.

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