Universal wall panel and method for fabricating same

Abstract

The invention relates to the field of building, and more particularly to the creation of permanent concrete formwork, as well as to hybrid precast construction, and can be used, in particular, for constructing homes and a variety of different buildings and structures, and for fabricating parts and elements of buildings and components of built structures from concrete or other building mixtures. The technical result of the invention is that of reducing fabrication times and labour costs entailed in the fabrication of formwork for load-bearing building elements and wall elements and providing for the required high performance characteristics of such building elements. A universal wall panel printed using a 3D printer comprises two side walls spaced apart widthwise from one another, wherein the inner surfaces of said side walls are connected by cross-members, resulting in the formation of an inner space formed by the cross-members and the side walls, and further comprises projecting opposing ends of the side walls at the end faces thereof, wherein the outer surface of the side walls is smooth, and the inner active surface of the side walls has natural furrows which enhance the bonding of a filler to the walls of the formwork. The panel may have any shape.

Description

[0001] Universal wall panel and its manufacturing method

[0002] Field of technology

[0003] The invention relates to the field of construction, namely to the construction of permanent concrete formwork, as well as to precast monolithic construction and can be used, in particular, for the construction of residential buildings, buildings and structures for various purposes, the manufacture of parts and elements of buildings, parts of building structures from concrete or other building mixtures.

[0004] State of the art

[0005] A multilayer wall panel is known from the prior art (see [1] Russian Federation Patent for Invention No. 2336395, IPC E04C2 / 284, E04B2 / 84, published on 20.10.2008) containing interconnected layers, one of which is load-bearing and formed between removable formwork, and the other is heat-insulating, characterized in that the load-bearing layer is made internally of expanded clay concrete with reinforcement located inside it from PVC pipes installed in the vertical direction, and from metal rods laid in the horizontal direction, the heat-insulating layer is made of foam plastic, in which communications are laid, additionally the multilayer wall panel contains a facade layer of moisture-resistant gypsum fiber sheet (GVLV), a reinforcing layer of fine-mesh fiberglass mesh, a heat-, moisture- and sound-insulating layer of extruded polystyrene foam, a layer for interior finishing made of moisture-resistant gypsum plasterboard (GKLV), with the layers connected to each other by gluing,and on top, between the heat, moisture and sound insulating layer of extruded polystyrene foam and the heat insulating layer of foam plastic, a cavity is formed by making a facade layer of gypsum fiber board with a heat, moisture and sound insulating layer of extruded polystyrene foam and a heat insulating layer of foam plastic with a layer for interior finishing made of gypsum fiber board that is greater in height than the internal load-bearing layer of expanded clay concrete.

[0006] The disadvantage of the above technical solution is that removable formwork and different technologies for the production of each layer are used to manufacture the panel, which increases the production time and labor costs. In addition, the panel production technology does not allow for flexible variation of their shape and configuration without increasing the time and labor costs required for this. Also, no method has been proposed to ensure sufficient adhesion of the concrete layer to the formwork layers.

[0007] A permanent formwork kit is known from the prior art (see [2] Russian Federation Patent for Invention No. 2459913, IPC E04B2 / 84, E04C1 / 00, E04B5 / 36, published on 27.08.2012), including a main wall block, a universal fastener for fastening wall blocks together, an over-aperture lintel and a floor-roof block, characterized in that the permanent formwork blocks are made of rigid polyurethane foam, which has high thermal insulation and noise-absorbing properties with increased chemical resistance to the effects of salts found in concrete (foam concrete), and also have a decorative finish on the front side of the outer surface in factory conditions together with the block, and on the inside the block has a fused sheet on its surface, profiled according to the surface geometry, and / or an expanded metal sheet, and / or fine mesh net.

[0008] The disadvantage of the above technical solution is that the permanent formwork is made of low-strength material, which complicates, for example, the installation of various equipment on the walls of buildings. Also, the proposed formwork material causes technological complexity in the manufacture of panels of complex shape and the associated high time and labor costs. In addition, the choice of heat and sound insulating materials is limited only to polyurethane foam, proposed in the invention. And also, a method for ensuring sufficient adhesion of the concrete layer to the formwork layers is not proposed.

[0009] Also known from the prior art is a method for erecting monolithic walls of residential buildings, structures and structures in permanent formwork (see [3] Russian Federation Patent for Invention No. 2387762, E04B2 / 84, published on 27.04.2010), including the installation of a formwork panel with the distance between the panels fixed with clamps at the time of pouring concrete, characterized in that the internal panels are installed in a row on the technological horizon first on the mortar level along the entire perimeter of the house, including the load-bearing partitions, then the insulation is secured on the side of the concrete pouring, taking into account the provision of overlap with the insulation of the next upper row, external cladding panels are installed, made specially with reinforcement protruding on the non-front side, intended for laying the horizontal reinforcement of the walls, and with cylindrical recesses of two at the top and bottom of the panel, into which rods are installed, providing the necessary gap between the panels,the facing panels are installed vertically using clamps, for example, from knitting wire, one end of which is tied to a rod inserted into the recess of the facing panel, and the second, after reaching verticality, is fixed with a nail to the upper end of the inner panel, the reinforcement of the walls is laid as the facing panels are installed on the reinforcement protruding from the facing and is hooked to the ends of the adjacent reinforcement, the gaps between the facing panels are plugged with rubber or plastic hoses (tubes) of the appropriate diameter, which are removed after the concrete has hardened and prepared for further use, the concrete is poured after preparing one or several rows, up to an entire floor.

[0010] The disadvantage of the above method is that panels are used as formwork, which greatly complicates (increases time and labor costs) the production of walls with curvilinear complex shapes. Also, no method has been proposed to ensure sufficient adhesion of the concrete layer to the formwork layers.

[0011] The closest analogue taken as a prototype is the method of concreting structures using permanent reinforced concrete and (or) reinforced cement formwork (see [4] Russian Federation patent for invention No. 2468158, E04B2 / 84, published on 27.11.2012), including the treatment of the active surface of the formwork with the application of vertical grooves and the laying with vibration of the concrete mixture in the formwork, characterized in that before laying the concrete mixture in the permanent reinforced concrete and (or) reinforced cement formwork, the concrete mixture is subjected to preliminary electrical heating with alternating current to temperatures exceeding the temperature of the active surface of the formwork by 25-45°, and the treatment of the active surface of the formwork is carried out with a high-pressure water jet of 8-16 atm 4-8 hours after the formation of the deck, while the application of additional inclined grooves to the active surface of the formwork is carried out at an angle of 45±15° in relation to the vertical grooves, and vertical and inclined grooves are applied by mechanical cutting.

[0012] The disadvantage of the above method is that the processing of the inner surface of the formwork (applying grooves) to ensure sufficient adhesion of the main concrete layer to the formwork layers is a technologically complex operation that slows down the manufacturing process of the product.

[0013] The essence of the invention

[0014] The objective of the claimed invention is to eliminate the shortcomings of analogues and the prototype, as well as to create the possibility of manufacturing a universal wall panel that simultaneously carries the functions of permanent formwork and a wall panel for building elements, including load-bearing ones, with a complex geometric shape without increasing the time and labor costs required for this in comparison with similar elements of simple shape. Also, the objective of the invention is to ensure the necessary adhesion of the internal concrete layer to the formwork layers without the need to use additional technological operations.In addition, the invention allows for the production of wall panels without restrictions on the noise and heat insulation fillers used, while the panel itself, described in the invention, has a permanent concrete formwork in its design, i.e. it provides high load-bearing and operational characteristics of the walls of the building, and allows for the combination of formwork for load-bearing and non-load-bearing sections of the wall into one element, facilitating and accelerating installation work.

[0015] The technical result of the invention is to reduce the manufacturing time and labor costs in the manufacture of a formwork element, and to ensure the required high and operational characteristics of building elements. The said technical result is achieved due to the fact that the universal wall panel printed on a 3D printer contains two side walls located at a distance in width from each other, wherein the inner surfaces of said side walls are connected by means of jumpers with the formation of an internal space formed by the jumpers and side walls, and protruding opposite ends of the side walls, wherein the outer surface of said side walls is made smooth, and the inner, active surface of said side walls is made with natural depressions that improve the adhesion of the filler to the formwork walls.

[0016] Natural depressions are made in the form of a furrow of the required shape.

[0017] The lintels are made of metal or non-metal reinforcement.

[0018] The lintels are made of concrete mix, printed on a 3D printer.

[0019] The resulting internal space between the lintels is filled with filler.

[0020] The resulting internal space between the lintels is filled with filler and reinforcement.

[0021] Concrete, foam concrete, polystyrene foam, and foam glass granulate are used as fillers.

[0022] At the ends of the panel there are protrusions formed by the side walls.

[0023] The side walls have an internal niche for filling with insulation or sound insulation.

[0024] The method for manufacturing a universal wall panel includes the following stages:

[0025] - printing on a 3D printer of the side walls of a wall panel, located at a distance in width from each other and connected by lintels, using layers of concrete successively laid on top of each other to form an internal space formed by lintels and side walls, and protruding opposite ends of the side walls. Forming the layers during the printing process in such a way that grooves are formed on the internal surfaces of the side walls of the panel. Depending on the design of the panel and the required properties, reinforcement is laid between the layers (in the transverse, longitudinal direction);

[0026] - hardening of concrete and formation on the inner surfaces of the side walls of the formwork element after hardening of concrete of natural convexities of the side part of the layers and natural depressions between the layers, formed during the process of molding the mixture during printing;

[0027] - Installation of a reinforcing frame into the cavity of the printed formwork (if the wall panel must perform load-bearing functions);

[0028] - Filling the internal cavity of the panel (formwork) with filler (concrete or insulation). Natural depressions are made in the form of a furrow of the required shape.

[0029] The lintels are made of metal or non-metal reinforcement, laid in the concrete layer of the side walls during the 3D printing process.

[0030] The lintels are made of concrete mix, printed on a 3D printer together with the side walls.

[0031] The resulting internal space between the lintels is filled with filler.

[0032] The resulting internal space between the lintels is filled with filler and reinforcement

[0033] Brief description of the drawings

[0034] Fig. 1 - General view of the design variant of the universal wall panel.

[0035] Fig. 2 - version of the universal wall panel.

[0036] 1 - side walls of the panel; 2 - end crossbars; 3 - internal crossbars;

[0037] 4 - protrusions on the ends of the panel; 5 - cavity for filling with filler;

[0038] 6 - cavity for reinforcement cage; 7 - additional wall; 8 - additional cavity; 9 - groove.

[0039] Fig. 3 - a variant of a wall made of two universal panels.

[0040] 10 - universal wall panel; 11 - concrete filler; 12 - reinforcement frame.

[0041] Implementation of the invention

[0042] A universal wall panel printed on a 3D printer comprises two side walls (1) located at a distance in width from each other. The inner surfaces of said side walls (1) are connected by means of crossbars (2, 3) to form an inner space formed by the crossbars (2, 3) and the side walls (1), and protruding opposite ends of the side walls (4) at the ends, wherein the outer surface of said side walls (1) is made smooth, and the inner, active surface of said side walls (1) is made with natural depressions - grooves (9).

[0043] Natural depressions are made in the form of a furrow of the required shape. Depending on the design of the extruder forming organ, the shape of the furrows can be any, for example, V-shaped, rectangular, round, etc.

[0044] The side walls (1) are made in the form of sheet material made of concrete and can be of any shape, for example: rectangular with side walls protruding beyond the overall dimensions in width and length at the ends; rectangular with side walls not protruding beyond the overall dimensions in width and length at the ends; rectangular with side walls protruding beyond the overall dimensions in length; non-rectangular with side walls protruding in such a way that when joined with other side walls a closed formwork contour is formed. The panel can have an additional wall (7) forming a cavity (8) with any of the walls (1) for filling with heat or noise insulation.

[0045] The jumpers (3) are made of metal or non-metal reinforcement.

[0046] The lintels (3) are made of concrete mix, printed on a 3D printer.

[0047] The resulting internal space between the jumpers (5) is filled with filler.

[0048] The resulting internal space between the lintels (5) is filled with filler and reinforcement.

[0049] The method for manufacturing a universal wall panel element includes the following stages:

[0050] - printing on a 3D printer of the side walls (1) of the wall panel, located at a distance in width from each other and connected by lintels (2, 3), using layers of concrete successively laid on top of each other to form an internal space (5) formed by the lintels (2, 3) and the side walls (1), and protrusions on the ends of the panel (4), forming a cavity (6) for the reinforcement frame (12);

[0051] - hardening of concrete and formation on the inner surfaces of the side walls (1) of the formwork element after hardening of concrete of natural convexities of the side part of the layers and natural depressions (9) between the layers, formed during the process of deformation of the mixture, while the outer side surfaces (1) after hardening are made smooth.

[0052] The jumpers (3) are made of metal or non-metal reinforcement.

[0053] The lintels (3) are made of concrete mix, printed on a 3D printer.

[0054] The resulting internal space between the jumpers (5) is filled with filler.

[0055] The resulting internal space between the lintels (5) is filled with filler and reinforcement

[0056] The side walls (1) of the permanent formwork element are manufactured by 3D printing on a construction 3D printer, which allows for the implementation of any panel shape. The side walls consist of an outer, smooth surface and an inner surface with natural indentations. During concrete extrusion during the printing process, the molding devices of the 3D printer form a certain thickness of the layer of concrete mixture being laid for the future side wall (1) of the permanent formwork element in one pass. To form the required height of the future side wall, the molding devices of the 3D printer form several layers of concrete mixture. As a result of printing several layers of concrete mixture on the inner surfaces of the side walls (1) of the formwork element, after hardening, natural convexities of the side part of the layers and indentations (9) between the layers formed during the deformation of the mixture remain, and the outer side surfaces of the formwork layers are smoothed to a flat plane (Fig. 2).In this case, the 3D printing process can also print the lintels (2, 3) together with the side walls (1, 7), or the lintels (3) made of metal or non-metal reinforcement are laid on a layer of concrete and after the concrete has hardened, the lintels (3) are fixed in the side walls. As a result of connecting several elements by joining the protruding ends, a single structure (Fig. 3) of formwork for load-bearing elements of a building, such as columns and walls, is formed. The formation of a formwork element is carried out using a 3D printer containing a forming device. In this case, sequential printing of layers is carried out for each side wall (1, 7) of the formwork element by passing the printer along the length of the future side walls. The number of passes depends on the required height of the side walls (1, 7) of the formwork element.A reinforcement cage (12) is installed in the space formed by connecting the protruding end elements (4) between the side walls (1) and the lintels, and then the space is filled with concrete (1 1). Ordinary concrete, expanded polystyrene, foam glass granulate, and other heat- or noise-insulating materials are used as a filler for the internal cavities (5). The additional cavity (8) is filled with heat- or noise-insulating materials.

[0057] Thus, the claimed invention allows to reduce the manufacturing time and labor costs in the manufacture of formwork and wall panels due to the use of a universal wall panel manufactured by the 3D printing method, and to ensure the required high and operational characteristics of building elements due to the implementation of grooves on the internal surfaces of the formwork, ensuring the adhesion of the active layer of the formwork and the poured concrete. Also, the claimed invention allows to reduce the weight of the buildings and structures being erected, thereby reducing the costs of making the foundation, increasing the speed of installation, due to the fact that the universal wall panels described in the invention have load-bearing formwork elements made of high-strength concrete, the internal space of the panels is filled with lightweight insulation, and the shape of the panels allows for the simultaneous installation of load-bearing building elements and wall elements.

Claims

CLAUSE OF INVENTION 1. A universal wall panel printed on a 3D printer and comprising two side walls located at a distance in width from each other, wherein the inner surfaces of said side walls are connected by means of crossbars to form an inner space formed by the crossbars and side walls, and protruding opposite ends of the side walls at the ends, wherein the outer surface of said side walls is made smooth, and the inner, active surface of said side walls is made with natural depressions.

2. The panel according to item 1, characterized in that the natural depressions are made in the form of a groove of the required shape.

3. The panel according to item 1, characterized in that the lintels are made of metallic or non-metallic reinforcement.

4. The panel according to item 1, characterized in that the lintels are made of concrete mixture printed on a 3D printer.

5. The panel according to item 1, characterized in that the formed internal space between the lintels is filled with filler.

6. The panel according to item 1, characterized in that the formed internal space between the lintels is filled with filler with reinforcement.

7. The panel according to item 1, characterized in that concrete, expanded polystyrene, or foam glass granulate are used as filler.

8. The panel according to item 1, characterized in that the opposite ends of the side walls, protruding along the ends, are made with an extension.

9. The panel according to claim 1, characterized in that it additionally contains a side wall installed between the main side walls or outside one of the main side walls to form an additional cavity.

10. A method for producing a universal wall panel using a 3D printer, which includes the following stages: - printing on a 3D printer of the side walls of a wall panel, located at a distance in width from each other and connected by lintels, using layers of concrete successively laid on top of each other to form an internal space formed by the lintels and side walls, and protruding opposite ends of the side walls at the ends; - hardening of concrete and formation on the inner surfaces of the side walls of the formwork element after hardening of concrete of natural convexities of the side part of the layers and natural depressions between the layers, formed during the process of deformation of the mixture. 1 1. The method according to item 10, characterized in that the natural depressions are made in the form of a furrow of the required shape.

12. The method according to item 10, characterized in that the lintels are made of metal or non-metal reinforcement, laid in the 3D printing process in the concrete layer of the side walls.

13. The method according to item 10, characterized in that the lintels are made of concrete mixture, printed on a 3D printer together with the side walls.

14. The method according to item 10, characterized in that the formed internal space between the lintels is filled with filler.

15. The method according to item 10, characterized in that the formed internal space between the lintels is filled with filler with reinforcement.

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