Method for producing building panels

Abstract

The invention relates to building, and more particularly to producing building panels. The technical result of the invention is that of reducing manual labour and simplifying and accelerating the process of producing a building panel. A method for producing a building panel comprises the following steps: a) forming an inner layer of a building panel with the desired overall dimensions by placing functional elements from a prefabricated set next to one another in a formwork; b) filling the formwork with a fixative material to connect the functional elements to one another and to form outer layers of a building structure.

Description

[0001] METHOD OF MANUFACTURING CONSTRUCTION PANELS

[0002] AREA OF TECHNOLOGY

[0003] The invention relates to construction, in particular to the production of building panels.

[0004] LEVEL OF TECHNOLOGY

[0005] Today, one of the main trends in the construction industry is aimed at reducing the share of manual labor, due to the fact that large-sized building elements are manufactured in factories and subsequently used at the construction site (PreFab production). However, such methods basically repeat in one form or another the construction methods previously used at construction sites. Therefore, they do not provide a significant improvement, acceleration or reduction in the cost of construction, since they either retain the amount of manual labor unchanged, but already at the production site, or require very expensive and complex automated production, when in fact the technological processes usually performed by human hands are imitated.

[0006] At the same time, the overwhelming majority of industrially mass-produced building materials, such as plasterboard sheets, plywood, sheets of other building materials, boards of various sizes, including those glued together from several pieces, and the like, are universal, applicable for any tasks, but at the same time require a very large amount of manual labor when using them. Today, the construction industry has taken the path of simplifying and reducing the cost of industrial production of building materials, the use of which retains the high complexity of their use with a high share of manual labor or with a high share of operations comparable to manual labor. Previously, such a strategy was justified in the presence of a cheap and mass market of manual labor workers. However, recent decades have shown a significant increase in the cost of manual labor and a shortage of workers in almost all countries of the world.This is one of the reasons for the already clearly emerging trend of falling labor productivity in construction over the past 30 years.

[0007] Also, the versatility of today's building products results in large amounts of waste, often not recycled. In today's climate of CO2 emissions control and circular economy requirements, there are limitations to the use of such old industrial approaches.

[0008] Therefore, new methods of manufacturing structures for subsequent assembly of buildings are needed, which can be made customized and used with a minimum amount of manual labor. Today, all kinds of 3-layer panels have become widespread. At the same time, they remain standardized, which continues to require a large amount of manual labor, in particular for the installation of internal structural systems.

[0009] The term “customization” here and below will mean the possibility of manufacturing products necessary for a specific project without any special subsequent modifications, while some design restrictions are allowed, taking into account the use of elements manufactured according to a given technical solution. Such design restrictions are not significant or do not significantly narrow possible design solutions.

[0010] A method for producing a building panel is known from the prior art, disclosed in US 9649662 B2, 22.05.2014. The method includes placing layers of concrete on a sheet of insulating material, followed by leveling and hardening the concrete layer.

[0011] This solution is typical and the disadvantage of the above method is that the inner layer is considered as a uniform, standard layer. When introducing the condition of customization of the panels produced, it is necessary to use a large amount of manual labor, in particular for the placement of any engineering system in such a panel. A durable layer applied to a standard insulation sheet can have a special reinforcing groove, which cannot be considered as a serious rib reinforcement that allows making the entire durable layer less thin.

[0012] In addition, a method for producing a building panel disclosed in US 2010 / 050555 A1, 04.03.2010, which can be considered a prototype, is known from the prior art. The method for producing a building panel includes producing a heat-insulating layer with subsequent application of concrete to at least one surface of the heat-insulating layer.

[0013] The disadvantage of the above method is also the use of a standard product made of insulating material used to form the inner layer. During the production of panels, such products are additionally processed to form a certain type of channels, which subsequently, after filling and hardening of the fixing material inside the channels, form rib reinforcement. But in any case, this implies first mass industrial production of a standard insulating material, which is then further processed before panel production.

[0014] DISCLOSURE OF INVENTION

[0015] The objective of the claimed invention is to reduce the share of manual labor in the production of customized large-format building products without using the currently accepted standard simple elements that require a large share of manual labor.

[0016] The technical result of the invention is a reduction in the share of manual labor, simplification and acceleration of the process of manufacturing a building panel.

[0017] The specified technical result is achieved due to the fact that for the production of building products, sets of prefabricated functional panel elements (FPE) of different types are used, which, depending on the location of placement in the building product and the requirements imposed on the product, perform a certain function in this place of the product. Thus, the method for producing building panels contains the following actions: a) Forming the inner layer of the building panel of the required overall dimensions by placing functional elements from a prefabricated set next to each other in the formwork; b) Filling the formwork with a fixing material for connecting the functional elements to each other and forming the outer layers of the building structure.

[0018] The use of one or another FPE inside the panel ensures customization of the manufactured panel. Sets of functional elements are intended to perform a construction, engineering, architectural or design function inside the panel.The set of functional elements is represented by the following groups: functional elements for a blind section of a wall, functional elements for installing a window / door, functional elements for connecting a panel to a column, functional elements for longitudinal joining of adjacent panels, functional elements for connecting panels at an angle of 90° / at an angle less than 90° / at an angle greater than 90°, functional elements for installation along the upper or lower edge of a wall panel, functional elements for a blind section of a floor panel, functional elements for organizing an opening in a floor panel, functional elements for stair flights, a functional element with openings and channels for laying utility systems and / or installing structural elements and / or placing fastening and / or slinging units, architectural and decorative functional elements.

[0019] The basic width of the functional elements (FPE) is set as 300 mm (in the metric system or 1 foot - 304.8 mm, in the imperial system), and it is also allowed to use FPEs with a width multiple of the basic width of the elements, for example 600 or 900 mm or 2' or 3' and more, or having a multiple of a reduced width, for example 1 / 2, or 1 / 3, or 1 / 4, or another value, from the basic width of the elements. The thickness of the functional elements determines the thickness of the panel, for which the insulating parameters and design parameters are important. The characteristics of the insulating material used determine the required thickness to obtain the desired properties of the panel. Therefore, for specific climatic zones or specific engineering requirements, their own sets of FPE of a certain thickness will be produced.

[0020] The length of functional panel elements is determined by the function they perform or the conditions of transportation, and can be equal to 1 or 1.2 meters when transported on pallets, or equal to 6, 10, or 12 meters when transported in trucks. FPE can be manufactured to a specific order with the required length. If the FPE is not long enough when used, they are assembled from several elements, joining them along the length; if the length is longer than necessary, the excess part is cut off and used later.

[0021] The use of prefabricated FPE kits allows the production of a customized panel by assembling the necessary FPEs and then fastening them into a single structure. The use of the assembly process in the production of a customized panel makes it possible to refuse special finishing with the help of a large amount of manual labor.

[0022] The functional elements are made of insulating or insulating-structural materials to obtain the required strength and heat or sound insulation properties of the panel, selected from the groups: porous or foamed or extruded polystyrene / polypropylene / polyurethane / polyethylene and insulating plastics, including recycled ones, including those containing reinforcing fiber; on plant or organic or chemical raw materials - sawdust, straw, husks, chaff, fibers, plant waste, including recycled ones - paper, textile waste, including pressed and / or glued, including using mineral and / or polymer-mineral binders; fiberglass or basalt fiber; based on mineral and polymer-mineral binders - cement, gypsum, magnesia, lime or ceramic, including their porous, foamed, aerated, volumetrically structured modifications, including those containing reinforcing fiber.

[0023] Also, functional elements can be manufactured as vacuum-filled, hollow-core elements made of steel.

[0024] In this case, the inner layer of the construction panel consists of a set of functional elements, in which at least one functional element differs from the others (has a different function). Functional elements may additionally already contain a fixing material in their design. For example, a functional element intended for installation in a window panel will already contain a layer of fixing material on which the window will be installed and fixed.

[0025] The following are used as a fixing material: concretes and composite materials containing a matrix of mineral or polymer-mineral binders or polymer substances and fillers, including reinforcing fiber; composite polymer materials containing a matrix of UV-curable polymer with fillers, including reinforcing fiber; composite polymer material in the form of an applied mass or sheet materials containing a matrix of heat-shrinkable polymer and fillers, including reinforcing fiber; composite polymer material containing a matrix of recycled polymer and fillers, in the form of an applied mass or sheet materials; varnishes, mastics, adhesives, including composite materials containing a matrix based on them and a filler, including reinforcing fiber.

[0026] The surfaces of the FPE facing the fixing material contain longitudinal and / or transverse grooves having a cross-sectional shape selected from the group: rectangle, trapezoid, T-shaped or rounded. After filling the grooves with the fixing material and its hardening, the fixing material forms a rib reinforcement of the surface layers of the building structure.

[0027] Before filling with a fixing material, grooves for laying engineering systems can be additionally formed on at least one surface of the formed inner layer of the building panel and / or in the side surface of the FPE, which can be easily carried out automatically without the use of manual labor.

[0028] Before filling with fixing material, pipes / channels / elements of engineering systems can be installed and fixed into the formed grooves on at least one surface of the formed inner layer of the building panel.

[0029] Before filling with the fixing material, reinforcing elements, meshes or structures made of materials selected from the group are placed on the surface of the formed inner layer: steel, glass or basalt-plastic materials, plastic fiber-reinforced composites, structures made of wood or plant materials, including glued ones. When forming a building panel, FPEs made of different materials can be used.

[0030] The outer layers of the building panel can be formed from different fixing materials.

[0031] The functional elements may additionally contain within themselves reinforcing elements or structures made of steel, wood or plant materials, glass or basalt-plastic materials, plastic fiber-reinforced composites, partially protruding beyond the dimensions of the main material of the functional elements and performing the function of connecting or fastening the layers of the fastening material together or the function of fastening the manufactured structures together.

[0032] For panels intended for external walls, when filled with fixing material, longitudinal vertical hollow channel gaps can be formed between the outer layer of fixing material facing the street and the functional elements, performing the function of a ventilated façade of the panel.

[0033] Additionally, structures made of durable material, steel, wood, glass or basalt-plastic materials, plastic fiber-reinforced composites, which connect the two main forming outer layers to each other, or which are intended to fasten the manufactured structures to each other, can be installed between the functional elements.

[0034] Before applying the fixing material to the surface of the formed inner layer of the building panel, elements are installed to perform rigging work and / or fasteners to connect the panels to each other and to other structural elements of the building.

[0035] The FPE can additionally have channels filled with fastening material, into which fasteners for suspended structures are subsequently installed.

[0036] A decorative coating is applied to the outer layers of the building panel.

[0037] The outer layers of the fixing material of the building panel can be formed in several different ways. In the first case, the required inner part from the FPE set is assembled in a horizontally located formwork, after which the first outer layer is formed with the fixing material on the surface of the formed inner part of the building panel, then after the first outer layer has hardened, the semi-finished structure is turned over and the second outer layer is formed in the formwork on the second surface of the formed inner layer of the building panel. The second method consists in the fact that the formwork is first filled with the fixing material, after which the inner layer is assembled on its surface from the FPE set, and then the second outer layer is formed on the second surface of the formed inner layer of the building panel.

[0038] The third method is that the panels are made in vertical cassette formwork, then the assembled inner part is installed in the formwork, after which the fixing material is poured onto both sides of the panel at once, forming two outer layers.

[0039] Before pouring the fixing material, the joints between the functional elements and the junctions of the functional elements to the formwork are filled or covered with a layer of material that prevents the fixing material from getting into the joints and junctions.

[0040] When filling with a fixing material, the formation of external end layers along the perimeter of the construction panel can be additionally carried out.

[0041] BRIEF DESCRIPTION OF DRAWINGS

[0042] The invention will be better understood from the description, which is not limiting in nature and is given with reference to the accompanying drawings, which show:

[0043] Fig. 1 - Section of the FPE for a blind section of a wall 300 mm wide

[0044] Fig. 2 - Section of the FPE for installing a window / door, the surface of the fastening material to which the window / door is installed is indicated in dark color.

[0045] Fig. 3 - Simple FPE for a blind section of a wall of small length: a) top view of a simple FPE for a blind section of a wall; b) section of a simple FPE for a blind section of a wall, where trapezoidal grooves are placed on the surfaces facing the fastening material.

[0046] Fig. 4 - Simple FPE for a blind section of a wall (general view).

[0047] Fig. 5 - FPE for joining blind panels at an angle of 90° (general view).

[0048] Fig. 6 - Section of the inner layer of the future building panel, for joining panels at an angle of less than 90°, assembled from the following FEP: corner element for joining panels at an angle of 90 degrees; element of a blind section of the wall; element of a blind section of the wall with a width of 1 / 2 of the base width; element for longitudinal joining of adjacent panels with a width of V2. of the base width of the FEP.

[0049] 1 - FPE for a blind section of a wall; 2 - longitudinal and transverse grooves; 3 - surface of the fastening material to which the window / door is installed; 4 - protrusions that remain when grooves are made on the FPE; 5 - half element for joining adjacent panels; 6 - corner FPE for joining panels at an angle of 90°; 7 - corner element for joining panels at an angle of 90°. EMBODIMENT OF THE INVENTION

[0050] The claimed method is implemented as follows. At the first stage, formwork is assembled, having the overall dimensions (width, length and height) of the future construction panel. Then, the inner layer of the panel is formed by laying functional elements from a set of different functional elements in the formwork, differing in the function performed in the future panel. In the formwork, the functional elements are installed next to each other, sequentially assembling several rows to the required dimensions of the future panel. In this case, the functional elements are laid in such a way that there is space left for pouring the first layer of the future panel. If necessary, space is also left between the surface of the inner layer of the panel and the walls of the formwork for pouring the fixing material into the specified space to form the outer end layers along the perimeter of the construction panel.

[0051] For example, a blind panel intended for a corner section of a house consists of the required number of functional elements for a blind section of a wall, with a functional element installed at one end of the panel for connecting panels at an angle of 90°, and a functional element installed at the other end of the panel for longitudinal joining of adjacent panels.

[0052] Another example, a blind panel for a wall in the middle of a house consists of the required number of functional elements for a blind section of the wall, and functional elements for longitudinal joining of adjacent panels are installed at both ends of the panel. Thus, the inner layer of the panel consists of a set of functional elements, in which at least one functional element differs from the rest (has a different function).

[0053] Then, a layer of fixing material, such as concrete, is poured onto the inner layer of the panel formed in the formwork, after which the first outer layer of the panel is formed.

[0054] Next, the formwork is disassembled, the formed blank is placed on the manufactured first outer layer, and the formwork is assembled again to form the second outer layer of the panel. After that, a layer of fixing material in the form of concrete is poured onto the second surface of the inner layer of the panel, after hardening of which the second outer layer of the panel is formed on the second surface. Next, the formwork is disassembled and the finished product in the form of a panel is removed, which consists of an inner layer, on the outer surfaces of which the outer layers are formed.

[0055] As a result of the above actions, a customized and ready-to-use construction panel is produced from a set of functional elements, each of which performs a specific function inside the panel. By assembling the functional elements in the manner described above, we form the full internal volume of the construction panel, including the necessary channels for engineering systems or with already installed engineering systems.

[0056] In addition, the finished product can be manufactured using another option, in which the inner layer is formed from a set of functional elements (as disclosed above) in the formwork on the already pre-poured first layer of the fixing material, forming the first outer surface, after which the second layer of the fixing material is poured, and after the hardening of the fixing material, the formwork is disassembled and the finished product is removed in the form of a panel, which consists of an inner layer and two outer surfaces.

[0057] The heterogeneity of the used FPEs is a significant difference from existing technologies, where panels are manufactured on the basis of homogeneous elements.

[0058] This approach allows very quickly and very simply, without the use of manual labor, to manufacture any customized panel that has all the built-in engineering or has the necessary grooves for its placement, has either a complete external and internal finish, or this finish has the highest degree of readiness.

[0059] This approach allows for the simple automation of the panel production process and a significant reduction in manual labor.

[0060] The invention has been disclosed above with reference to a specific embodiment thereof. Other embodiments of the invention may be obvious to specialists, without changing its essence as disclosed in the present description. Accordingly, the invention should be considered limited in scope only by the following claims.

Claims

CLAUSE OF THE INVENTION 1. A method for producing building panels comprising the following steps: a) Forming an inner layer of a building panel of the required overall dimensions by placing functional elements from a prefabricated set next to each other in formwork; b) Filling the formwork with a fixing material to connect the functional elements to each other and form the outer layers of the building panel.

2. The method according to claim 1, characterized in that the functional elements are intended to perform a construction, engineering, architectural or design function inside the panel, and the set of functional elements is represented by the following groups: functional elements for a blind section of a wall, functional elements for installing a window / door, functional elements for connecting a panel to a column, functional elements for longitudinal joining of adjacent panels, functional elements for connecting panels at an angle of 90° / at an angle less than 90° / at an angle greater than 90°, functional elements for installation along the upper or lower edge of a wall panel, functional elements for a blind section of a floor panel, functional elements for organizing an opening of a floor panel, functional elements for flights of stairs,a functional element with openings and channels for laying engineering systems and / or installing structural elements and / or placing fastening and / or slinging units, architectural and decorative functional elements.

3. The method according to any one of paragraphs. 1 or 2, characterized in that the functional elements are made of insulating materials selected from the groups: porous or extruded polystyrene / polypropylene / polyurethane / polyethylene and insulating plastics, including recycled ones, including those containing reinforcing fiber; on plant or organic or chemical raw materials - sawdust, straw, husks, chaff, fibers, plant waste, including recycled ones - paper, textile waste, including pressed and / or glued, including using mineral and / or polymer-mineral binders; fiberglass or basalt fiber; based on mineral and polymer-mineral binders - cement, gypsum, magnesia, lime or ceramic, including their porous, foamed, aerated, volumetrically structured modifications, including those containing reinforcing fiber; or functional elements are made as volumetric-hollow vacuum-sealed elements made of steel.

4. The method according to claim 1, characterized in that the following are used as the fixing material: concretes and composite materials containing a matrix of mineral or polymer-mineral binders or polymeric substances and fillers, including reinforcing fiber; composite polymeric materials containing a matrix of UV-curable polymer with fillers, including reinforcing fiber; a composite polymeric material in the form of an applied mass or sheet materials containing a matrix of heat-shrinkable polymer and fillers, including reinforcing fiber; a composite polymeric material containing a matrix of recycled polymer and fillers, in the form of an applied mass or sheet materials; varnishes, mastics, adhesives, including composite materials containing a matrix based on them and a filler, including reinforcing fiber.

5. The method according to any one of paragraphs 1-3, characterized in that the surfaces of the functional elements facing the fastening material contain longitudinal and / or transverse grooves having a cross-sectional shape selected from the group: rectangle, trapezoid, T-shaped or rounded, forming a rib reinforcement of the fastening material.

6. The method according to any of paragraphs 1-2, characterized in that before filling with a fixing material, grooves for laying engineering systems are formed on at least one surface of the formed inner layer of the building panel and / or in the side surface of the functional elements.

7. The method according to any of paragraphs 1-2, characterized in that before filling with the fixing material, at least on one surface of the formed inner layer of the building panel, pipes / channels / elements of engineering systems are installed and fixed in the formed grooves.

8. The method according to any of paragraphs 1-2, characterized in that before filling with the fixing material, reinforcing elements, meshes or structures made of materials selected from the group are placed on the surface of the formed inner layer: steel, glass or basalt-plastic materials, plastic fiber-reinforced composites, structures made of wood or plant materials, including glued ones.

9. The method according to any of paragraphs 1-3, characterized in that when forming the construction panel, a functional element made of different materials can be used.

10. The method according to any of paragraphs 1-4, characterized in that the outer layers of the building panel can be formed from different fixing materials.

11. The method according to any of paragraphs 1-3, characterized in that the functional elements additionally contain within themselves reinforcing elements or structures made of steel, wood or plant materials, glass or basalt-plastic materials, plastic fiber-reinforced composites, partially protruding beyond the dimensions of the main material of the functional elements.

12. The method according to any of paragraphs 1-3, characterized in that additionally, reinforcing elements or structures made of steel, wood or plant materials, glass or basalt-plastic materials, or plastic fiber-reinforced composites are installed between the functional elements.

13. The method according to any of paragraphs 1-2, characterized in that for panels intended for external walls, when filling with a fixing material, longitudinal vertical hollow channel gaps are formed between the outer layer of the fixing material and the functional elements, forming a ventilated facade of the panel.

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