Wall with high thermal and acoustic resistance

Abstract

The present invention describes a wall with high thermal and acoustic resistance, and is also based on the description of a new construction process for exterior walls in order to improve their efficiency.

Description

Wall with high thermal and acoustic resistance

[0001] The present invention describes a wall with high thermal and acoustic resistance and the method for obtaining thereof.

[0002] Walls play several essential roles in a house or dwelling. The most important functions are:

[0003] - Structure and Support: they provide structural support to the construction, helping to maintain the integrity and stability of the house, distributing the weight of the structure, and helping to resist external forces, such as wind and earthquakes.

[0004] - Space Division: used to divide the interior space, creating bedrooms, bathrooms, kitchens and other specific environments. They help to organize the house according to the needs and functions of each area.

[0005] - Thermal and Acoustic Insulation: well-built and insulated, walls contribute to thermal control, maintaining the internal temperature of the house, helping to reduce the transmission of noise between the different rooms, providing privacy and acoustic comfort.

[0006] - Protection and Security: They provide protection against the elements, such as rain, wind and snow, and help to maintain the security of the house, preventing unauthorized access and protecting against intrusions.

[0007] - Support for Electrical and Plumbing Installations: They house electrical and plumbing systems, such as electrical installations, water pipes and ventilation, providing a structure in which these components can be installed in an organized and safe manner.

[0008] - Aesthetics and Design: They contribute significantly to the overall aesthetics of the house; paint, cladding, textures and decorative elements can be applied to the walls to create a visually pleasing and personalized environment.

[0009] - Privacy and Intimacy: They play a crucial role in creating private spaces, ensuring the privacy of the house's occupants, helping to separate personal and social areas, creating a comfortable environment for the residents.

[0010] In short, walls are fundamental elements in the construction of a house, performing structural, aesthetic and practical functions to ensure comfort, security and functionality.

[0011] The present invention describes a wall with high thermal and acoustic resistance, and is also based on the description of a new construction process for exterior walls in order to improving their efficiency.

[0012] The wall with high thermal and acoustic resistance is characterized in that it comprises: a first set of rails on the outer portion of the wall, and a second set of rails on the inner portion of the wall, both sets of rails resting on a floor slab; at least one structural pillar, centrally disposed within the wall and between both sets of rails, and wrapped in projected polyurethane; a section of lightweight concrete comprised between a second section of expanded polystyrene with graphite, and a third section of expanded polystyrene with graphite; a first section of expanded polystyrene with graphite and an external cladding structurally separated from the first section of expanded polystyrene with graphite through the application of an Omega profile, promoting the creation of an air cavity, where the Omega profile is mechanically coupled to a rigid PVC U profile, and where the rigid PVC U profile is mechanically coupled to a rigid PVC profile; the rigid PVC profile promoting compact structural fixing between the first section of expanded polystyrene with graphite, the second section of expanded polystyrene with graphite, the lightweight concrete section and the third section of expanded polystyrene with graphite coupled sequentially; a metal upright profile positioned between the lightweight concrete section and the expanded polystyrene with graphite section; and a plasterboard section applied over the section of expanded polystyrene with graphite.

[0013] In one embodiment of the wall, the air cavity preferably has a width of 30mm.

[0014] In another preferred embodiment of the wall, the omega profile has a dimension of 70x30mm.

[0015] In another preferred embodiment of the wall, the rigid PVC profile preferably has a dimension of 40x2mm.

[0016] In another preferred embodiment of the wall, the first section of expanded polystyrene with graphite preferably has a width of 80mm.

[0017] In another preferred embodiment of the wall, the second section of expanded polystyrene with graphite preferably has a width of 40mm.

[0018] In another preferred embodiment of the wall, the third section of expanded polystyrene with graphite preferably has a width of 40mm.

[0019] In another preferred embodiment of the wall, the metal upright profile preferably has a width of 48mm.

[0020] In another preferred embodiment of the wall, the external cladding comprises at least one of granite slabs, ceramic slabs, fibre cement slabs, “Equitone”, wood cement slabs, or other technically adequate.

[0021] In another preferred embodiment of the wall, the plasterboard sheets are cladded with paint, another type of finish, wood panel, wood and cement composite panel.

[0022] In another preferred embodiment of the wall, the lightweight concrete comprises a volumetric mass of 460 kg / m3, are preferably composed of 80 kg of cement, 1.055 m3of expanded clay, and 125 litres of water.

[0023] In another preferred embodiment of the wall, the first section of expanded polystyrene with graphite, the second section of expanded polystyrene with graphite or the third section of expanded polystyrene with graphite comprise 25% recycled graphite.

[0024] The present invention further discloses the method of constructing the wall with high thermal and acoustic resistance previously described, characterized in that it comprises the steps of installation of a first set of rails on the outer portion of the wall, and a second set of rails on the inner portion of the wall, both sets of rails resting on a floor slab and between which at least one structural pillar is positioned, centrally arranged inside the wall, and wrapped in projected polyurethane; placing a section of lightweight concrete comprised between a second section of expanded polystyrene with graphite, and a third section of expanded polystyrene with graphite; installation of a first section of expanded polystyrene with graphite and an external cladding structurally separated from the first section of expanded polystyrene with graphite through the application of an Omega profile, promoting the creation of an air cavity, where the Omega profile is mechanically coupled to a rigid PVC U profile, and where the rigid PVC U profile is mechanically coupled to a rigid PVC profile; installation of the rigid PVC profile promoting compact structural fixing between the first section of expanded polystyrene with graphite, the second section of expanded polystyrene with graphite, the lightweight concrete section and the third section expanded polystyrene with graphite coupled sequentially; installation of a metal upright profile positioned between the lightweight concrete section and the expanded polystyrene with graphite section; and installation of a plasterboard section applied over the expanded polystyrene with graphite section.

[0025] The thermal efficiency of walls is crucial to maintain thermal comfort inside a house and to optimize energy consumption. Some of the main problems that can affect the thermal efficiency of walls include:

[0026] - Poor thermal insulation: allows heat transfer between the inside and outside of the house, resulting in heat loss during the winter and heat gain during the summer, leading to an increase in energy consumption for heating or cooling the rooms of the house.

[0027] - Thermal Bridge: occurs in areas where the thermal barrier is interrupted, allowing direct heat transfer, occurring in places where there are interruptions in the insulating layer, such as poorly sealed corners, joints between different construction materials or areas where the walls are in contact with the ground.

[0028] - Air Infiltration: Air leaks through walls can compromise thermal efficiency, such as gaps, cracks or sealing failures that will allow the entry of external air, resulting in heat loss in winter and heat gain in summer.

[0029] - Inadequate Building Material: Certain building materials have better thermal properties than others, and the use of inadequate materials or the lack of adequate thermal insulation can negatively affect the thermal efficiency of walls.

[0030] - Lack of Thermal Barriers: Thermal barriers, such as reflective films or insulating layers, are designed to reduce heat transfer, and the absence of these barriers or their inadequate installation can compromise thermal efficiency.

[0031] - Orientation and Solar Exposure: Walls orientation regarding the sun and direct exposure to solar rails can influence thermal efficiency, so that walls facing south, for example, may receive more direct sunlight, which can affect the thermal balance.

[0032] - Local Climatic Conditions: The thermal efficiency of walls can be affected by local climatic conditions, such as strong winds, heavy rain and extreme temperatures.

[0033] To improve the thermal efficiency of walls, it is important to invest in quality insulation, ensure good sealing, use suitable materials and consider factors such as orientation and solar exposure during the planning and construction of the house.

[0034] This new technique then uses several layers of products on the market, the unexpected combination of which makes it possible to obtain a wall with high efficiency and thermal resistance.

[0035] This construction system functions as the “skin” of the building, has no support function and must be executed in an orderly manner in the various layers of its composition. Before implementing this construction system, the floor slabs and the building structure must be completed. There are several advantages related to the use of this building walls method, comprising, for example:

[0036] - Fast construction due to the high yield of the process;

[0037] - Quality assurance given by the use of high-resistance materials;

[0038] - Guarantee of cleanliness of the work as there is no waste;

[0039] - High fire resistance provided by used materials;

[0040] - High shock resistance and high durability;

[0041] - Low energy consumption in manufacturing;

[0042] - Lower concentration of labour;

[0043] - Choice of materials to achieve high thermal resistance;

[0044] For an easier understanding of the present application, figures are attached, which represent achievements that, however, are not intended to limit the technique disclosed here.

[0045] Illustrates a horizontal sectional view of the wall with high efficiency and thermal resistance.

[0046] Illustrates a vertical sectional view of the proposed wall.

[0047] Illustrates the first step of the wall construction process with high efficiency and thermal resistance.

[0048] Illustrates the second step of the construction process of the proposed wall.

[0049] Illustrates the third step of the construction process of the proposed wall.

[0050] Illustrates the fourth step of the construction process of the proposed wall.

[0051] Illustrates the fifth step of the construction process of the proposed wall.

[0052] Illustrates the sixth step of the construction process of the proposed wall.

[0053] Illustrates the seventh step of the construction process of the proposed wall.

[0054] Illustrates the eighth step of the construction process of the proposed wall.

[0055] With reference to the figures, some embodiments are now described in more detail, which are not intended, however, to limit the scope of the present application.

[0056] illustrates a horizontal sectional view of the wall (1) with high efficiency and thermal resistance. In this it is possible to check the positioning of the structural pillar (10), centrally placed inside the wall (1), and which is wrapped in projected polyurethane. As illustrated, sequentially from outdoor to indoor, the wall (1) comprises the installation of external cladding (11), a first section of expanded polystyrene with graphite (16), a second section of expanded polystyrene with graphite (17), a lightweight concrete section (18), a metal upright profile (20), a third section of expanded polystyrene with graphite (19) and a plasterboard section (21). The external cladding (11) is structurally away from the first section of expanded polystyrene with graphite (16) by the application of an Omega profile (13), promoting the creation of an air cavity (12). Additionally, the Omega profile (13) is mechanically coupled to a rigid PVC U profile (15). The rigid PVC U profile (15) is mechanically coupled to a rigid PVC profile (14). The rigid PVC profile (14) promotes compact structural fixing between the first section of expanded polystyrene with graphite (16), the second section of expanded polystyrene with graphite (17), the lightweight concrete section (18) and the third section expanded polystyrene with graphite (19).

[0057] The base support structure that allows this solution to be obtained is based on the use of a metallic structure, which provides speed in execution, ease of assembly and integration of the system as a whole. After the support structure is assembled, the pillars (10) are cladded with polyurethane designed to isolate it and reduce its thermal inertia.

[0058] shows a vertical sectional view of the wall facade, perfectly illustrating the sequence of components, from the outside to the inside, such as the external cladding (11), air cavity (12), a first section of expanded polystyrene with graphite (16), a second section of expanded polystyrene with graphite (17), a section of lightweight concrete (18), a third section of expanded polystyrene with graphite (19), and a plasterboard section (21), laid down on a floor slab (24).

[0059] illustrates the first step of the wall construction process (1), comprising the placement of a set of 90mm rails (22) on the external portion of the wall (1), and a set of 40mm rails (23) on the internal portion of the wall (1), both sets of rails (22, 23) resting on the corresponding floor slab (25). Between the sets of rails (22, 23), the structural pillars (10) are positioned. The sets of rails (22, 23) are built based on a cold galvanized steel metal profile measuring 90mm on the outside and 48mm on the inside. The sets of rails (22, 23) function as guides where the 80mm and 40mm EPS thermal insulation sections with Graphite (16, 17, 19) are placed and seated, in the form of a plate. These sections (16, 17, 19) are accompanied by rigid PVC “U” profiles (15) for the 80mm insulation on the outside, 48mm metal upright profiles (20) for the 40mm insulation on the inside (19), where they fit and are screwed to receive the next plate.

[0060] This assembly is illustrated in, where the placement of 80mm expanded polystyrene plates with graphite (16) on the external face of the wall is represented by applying the rigid PVC profiles (14, 15) screwed together. During assembly, the plate (16) is prepared to receive the next part.

[0061] illustrates the placement of 40mm expanded polystyrene with graphite plates (17) on the internal face of the wall, opposite to the 80mm expanded polystyrene plates with graphite (16), and their respective screwing to the PVC profiles rigid (14, 15).

[0062] illustrates the placement of 40mm expanded polystyrene plates with graphite (17) on the internal rail (23) applying the 48mm metal profiles (20) screwed together. During assembly, the plate (17) is prepared to receive the next part.

[0063] illustrates the placement of 70mmx30mm omega profiles (13) to receive the external finish that makes up the ventilated facade. In a preferred embodiment, and after placing the insulation on the outside and inside of the wall (1), the ventilated facade is placed on the outside. The 70X30mm omega profiles (13) are applied to the rigid PVC profiles (15) to achieve the final finish.

[0064] illustrates the placement of the external cladding (11) that makes up the ventilated facade, andillustrates the application of the BA 13 plasterboard (21) inside the wall (1) and which will receive the final finish. Preferably the finish may be varied, and may include granite slabs, ceramic slabs, fibre cement slabs, “Equitone”, wood cement slabs, etc. Plasterboard sheets (21) will be applied inside to provide the final finish (painting). It can also take another type of wood panel finish, wood and cement composite panel.

[0065] Finally, in, one of the preferred embodiments is illustrated, in which, for the exemplary case of a single-story dwelling, the interior of the wall facade is concreted with lightweight concrete (18). The lightweight concrete (18) comprises, in one of the preferred embodiments, a volumetric mass of 460 kg / m3, being preferably composed of 80 kg of cement, plus 1.055 m3of expanded clay, and a further 125 litres of water. This mixture may include the use of a concrete hardening accelerator. Preferably, concreting is carried out along the length of the wall, in sections of 30cm to 40cm up to the top. In the case of small wall segments, it can be concreted up to the top in one go.

[0066] In a two-story dwelling, concreting will be carried out through holes made in the floor slab, these holes being made every 60 cm to guarantee control.

[0067] In one of the preferred embodiments of the present invention, the expanded polystyrene sections (16, 17, 19) comprise the use of 25% recycled graphite in their structure, which promotes a thermal conductivity coefficient [λ] of 0.031 W / m.ºC. This means that, if we also add an 8cm section of graphite EPS to a simple wall, we will obtain a Thermal Transmittance Coefficient (U) of approximately 0.26 W / m2.ºC. This solution is, therefore, advantageous, since an EPS section without graphite has a [λ] of 0.036 W / m.ºC., and in the case of a single wall, when adding an 8cm section of EPS, we will obtain only a U (Thermal Transmittance Coefficient) of approximately 0.29 W / m2.ºC.

[0068] Given the conductivity coefficient of PVC (0.16 W / mK) compared to aluminium (206 W / mK), the ventilated facade presents better thermal behaviour than other construction systems since, when well insulated, it allows the circulation of rising air eliminating thermal bridges and condensation.

[0069] Still, the use of lightweight concrete with expanded clay presents advantages in relation to the use of a natural, ecological, long-lasting, non-combustible and inert product, which does not decompose or rot and is light”. This product has thermal conductivity 0.10 (W / m.ºC) and excellent acoustic properties. For example, with the proposed combination, the sound absorption coefficient of a 20cm wall at low frequencies (bass, 100-400Hz) is 0.48, at medium frequencies (medium, 400-160Hz) it is 0.59, and at high frequencies (treble,1600-500Hz) it is 0.59.

[0070] Considering a 10m2wall subject to an internal / external temperature difference of k=20 degrees where U x 10m2 x 20°= W results in the following comparative values:

[0071]

[0072] The present description is, of course, in no way restricted to the embodiments presented in this document and a person with average knowledge of the field will be able to foresee many modification possibilities without leaving the general idea, as defined in the claims. The preferred embodiments described above are obviously combinable with each other. The following claims further define preferred embodiments.

[0073] In the construction of buildings, apartments or houses.

[0074] 1 – proposed wall with high efficiency and thermal resistance;

[0075] 10 – structural pillar covered in projected polyurethane;

[0076] 11 – exterior cladding;

[0077] 12 – air cavity, preferably 30mm wide;

[0078] 13 – Omega profile, preferably 70x30mm;

[0079] 14 – rigid PVC profile, preferably 40x2mm;

[0080] 15 – rigid PVC U profile;

[0081] 16 – expanded polystyrene with graphite section, preferably 80mm wide;

[0082] 17 – expanded polystyrene with graphite section, preferably 40mm wide;

[0083] 18 – lightweight concrete section;

[0084] 19 – expanded polystyrene with graphite section, preferably 40mm wide;

[0085] 20 – 48mm metal upright profile;

[0086] 21 – BA 13 plasterboard section;

[0087] 22 – 90mm rails;

[0088] 23 – 40mm rails;

[0089] 24 – floor slab.

Claims

Wall (1) with high thermal and acoustic resistance characterized in that it comprises: a first set of rails (22) on the outer portion of the wall (1), and a second set of rails (23) on the inner portion of the wall (1), both sets of rails (22, 23) resting on a floor slab (25); at least one structural pillar (10), centrally disposed within the wall (1) and between both sets of rails (22, 23), and wrapped in projected polyurethane; a section of lightweight concrete (18) comprised between a second section of expanded polystyrene with graphite (17), and a third section of expanded polystyrene with graphite (19); a first section of expanded polystyrene with graphite (16) and an external cladding (11) structurally separated from the first section of expanded polystyrene with graphite (16) through the application of an Omega profile (13), promoting the creation of an air cavity (12), where the Omega profile (13) is mechanically coupled to a rigid PVC U profile (15), and where the rigid PVC U profile (15) is mechanically coupled to a rigid PVC profile (14); the rigid PVC profile (14) promoting compact structural fixing between the first section of expanded polystyrene with graphite (16), the second section of expanded polystyrene with graphite (17), the lightweight concrete section (18) and the third section of expanded polystyrene with graphite (19) coupled sequentially; a metal upright profile (20) positioned between the lightweight concrete section (18) and the expanded polystyrene with graphite section (19); and a plasterboard section (21) applied over the section of expanded polystyrene with graphite (19).Wall (1) according to claim 1, characterized in that the air cavity (12) preferably has a width of 30mm.Wall (1) according to claim 1, characterized in that the omega profile (13) preferably has a dimension of 70x30mm.Wall (1) according to claim 1, characterized in that the rigid PVC profile preferably has a dimension of 40x2mm.Wall (1) according to claim 1, characterized in that the first section of expanded polystyrene with graphite (16) preferably has a width of 80mm.Wall (1) according to claim 1, characterized in that the second section of expanded polystyrene with graphite (17) preferably has a width of 40mm.Wall (1) according to claim 1, characterized in that the third section of expanded polystyrene with graphite (19) preferably has a width of 40mm.Wall (1) according to claim 1, characterized in that the metal upright profile (20) preferably has a width of 48mm.Wall (1) according to claim 1, characterized in that the external cladding (11) comprises at least one of granite slabs, ceramic slabs, fibre cement slabs, “Equitone”, wood cement slabs, or other technically adequate.Wall (1) according to claim 1, characterized in that the plasterboard sheets (21) being cladded with paint, another type of finish, wood panel, wood and cement composite panel.Wall (1) according to claim 1, characterized in that the lightweight concrete (18) comprises a volumetric mass of 460 kg / m3, preferably composed of 80 kg of cement, 1.055 m3of expanded clay, and 125 litres of water.Wall (1) according to claim 1, characterized in that the first section of expanded polystyrene with graphite (16), the second section of expanded polystyrene with graphite (17) or the third section of expanded polystyrene with graphite (19) comprising 25% recycled graphite.Method of constructing the wall (1) with high thermal and acoustic resistance according to any of the previous claims 1 to 12, characterized in that it comprises the steps of installation of a first set of rails (22) on the outer portion of the wall (1), and a second set of rails (23) on the inner portion of the wall (1), both sets of rails (22, 23) resting on a floor slab (25) and between which at least one structural pillar (10) is positioned, centrally arranged inside the wall (1), and wrapped in projected polyurethane; placing a section of lightweight concrete (18) comprised between a second section of expanded polystyrene with graphite (17), and a third section of expanded polystyrene with graphite (19); installation of a first section of expanded polystyrene with graphite (16) and an external cladding (11) structurally separated from the first section of expanded polystyrene with graphite (16) through the application of an Omega profile (13), promoting the creation of an air cavity (12), where the Omega profile (13) is mechanically coupled to a rigid PVC U profile (15), and where the rigid PVC U profile (15) is mechanically coupled to a rigid PVC profile (14); installation of the rigid PVC profile (14) promoting compact structural fixing between the first section of expanded polystyrene with graphite (16), the second section of expanded polystyrene with graphite (17), the lightweight concrete section (18) and the third section expanded polystyrene with graphite (19) coupled sequentially; installation of a metal upright profile (20) positioned between the lightweight concrete section (18) and the expanded polystyrene with graphite section (19); and installation of a plasterboard section (21) applied over the expanded polystyrene with graphite (19) section.

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