Patent Application
20110185664
The present invention relates to construction technology. More particularly, this invention relates to an assembly unit for buildings that is configured to include: an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, which is inserted into the expanded synthetic resin, where a certain length of the bent portions is exposed from front and rear surfaces of the expanded synthetic resin; and a metal wire mesh mounted on the front and rear surfaces of the expanded synthetic resin and combined with the bent portions of the metal wire, to thereby secure working stability, so that an operator may carry it easily, shorten construction time by removing the necessity of a series of works of making a concrete form, casting concrete, and curing the concreted surface, improve surroundings, and reduce construction expenses, by simply using the expanded synthetic resin, the metal wire and the metal wire mesh, compared with those of when existing reinforced concrete structures are employed. Also, the present invention relates to the fabrication method of the assembly unit.
In general, buildings have been primarily constructed according to a reinforced concrete method. That is, the reinforced concrete structures are constructed as follows. Reinforced concrete frameworks are built to withstand the load of entire structures with pillars, beams, and slab formed by installing a concrete form starting from the lowermost floor, disposing reinforcing bars, casting concrete and curing the concreted surface, and releasing the form. Bricklaying is performed so as to be connected the reinforced concrete frameworks, and then, wall bodies are installed by using finishing materials such as mortar.
In more detail, first, the ground is dug and cast to form an underground floor, the reinforcing bars are disposed on the slab of the underground floor, and then wall body/pillar forms are installed.
Thereafter, slab/beam forms are installed at an upper portion of the wall body/pillar forms, and then, reinforcing bars are arranged in the slab/beam forms and connected to the reinforcing bars arranged in the wall body/pillar forms.
Next, concrete supplied by a concrete mixer is cast in the wall body/pillar/slab/beam forms and cured.
Through such processes, wall bodies, pillars, slab and beams are formed and a basic structure corresponding to a first floor of a building can be completed.
Thereafter, the forms are removed from the completed wall bodies, pillars, slab, and beams.
By repeatedly performing the processes, a multi-floor structure can be completed.
However, the conventional building construction method in which the wall body/pillar forms are installed, on which the slab/beam forms are then installed, the reinforcing bars in the wall body/pillar forms and those in the slab/beam forms are connected, the concrete is cast, and then the concrete surface is cured, causes many problems. This is, because the intensity work is high, worker absenteeism is also high and thus labor costs increase. In addition, the required lengthy construction time results in degradation of surrounding area, possibly including natural areas. In addition, construction expenses increase because of the use of the frameworks of the building, namely, the reinforcing bars and the concrete.
Thus, recently, in an effort to address these problems, a constructing method using a pre-cast concrete structure has come into use.
The pre-cast concrete constructing method is a technique for previously creating structures in a factory with pre-cast concrete block facilities and transferring the created structures to a construction site and successively assembling them. This method obtains quality stability, improvement of construction characteristics, standardization, and improvement of working conditions at the construction site.
However, although the pre-cast technique is aimed to partially construct structures, it has a problem in that since the structures are large, it is not easy to transport the structures from the factory to the construction site. In addition, a large crane is required for construction but such a crane cannot be used in alleys or in a high density downtown area, hindering construction.
The present invention solves the above problems, and provides an assembly unit for buildings and its fabrication method that can shorten the construction duration by omitting a series of works of making a concrete form, cast concrete, and cure the concreted surface, etc.
The present invention further provides an assembly unit for buildings and its fabrication method that can facilitate transportation of frame panels during operations by reducing the weight of the frame panels.
The present invention further provides an assembly unit for buildings and its fabrication method that can accomplish good sound-proofing without having a soundproofing device by filling the interior of a frame panel with an expanded synthetic resin.
In accordance with an exemplary embodiment of the present invention, the present invention provides an assembly unit for buildings, including an expanded synthetic resin; a metal wire bent in a zigzag manner to have bent portions, which is inserted into the expanded synthetic resin, where a certain length of the bent portions is exposed from both front and rear surfaces of the expanded synthetic resin; and a metal wire mesh covering both front and rear surfaces of the expanded synthetic resin and fixedly combined with the bent portions of the metal wire.
Here, a first mixture, which has been composed by adding 6˜13 wt % of SiO2, 0.1˜0.8 wt % of Al2O3, 0.01˜0.08 wt % of Fe2O3, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K2O, 0.005˜0.05 wt % of TiO2, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO3 to 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, is first coats both the front and rear surfaces or one of the front and rear surfaces of the expanded synthetic resin and on the surface of the metal wire mesh. A second mixture, which has been composed by adding 10˜20 wt % of SiO2, 0.3˜0.9 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K2O, 0.005˜0.06 wt % of TiO2, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na2O, 0.001˜0.007 wt % of ZrO2, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO3 to 66.218˜84.557 wt % of silica sand of 0.1˜1.5 mm, secondly coats the first coating. In addition, a third mixture, which has been composed by adding 17˜25 wt % of SiO2, 0.2˜0.15 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K2O, 0.01˜0.07 wt % of TiO2, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO3 to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, thirdly coats the second coating.
In accordance with another exemplary embodiment of the present invention, the present invention provides a method for fabricating an assembly unit for buildings, including: forming bent portions by bending a metal wire in a zigzag manner (S100); fixing the bent metal wire within a mold for shaping an expanded synthetic resin (S200); injecting a synthetic resin and a foaming agent into the mold such that a certain length of the bent portions of the metal wire are exposed from front and rear surfaces of the expanded synthetic resin to thus mold the expanded synthetic resin (S300); positioning a metal wire mesh on both front and rear surfaces of the expanded synthetic resin (S400); and welding the bent portions of the metal wire and the metal wire mesh to fix the metal wire mesh on both front and rear surfaces of the expanded synthetic resin (S500).
As described above, the assembly unit for buildings and the fabrication method according to the present invention has the following advantages.
First, since the panel for buildings is light, a worker can easily carry it, and thus, a working stability can be secured.
Second, since a series of works of fabricating a concrete form, casting concrete, and curing concreted surface are not required, the construction duration can be considerably shortened, and accordingly, the surrounding environment is not degraded.
Third, since the frame panel includes the expanded synthetic resin, the metal wire, and the metal wire mesh, the construction expenses can be reduced, compared with the conventional reinforced concrete structure.
Fourth, when the frame panel filled with the expanded synthetic resin is applied to a building, good soundproofing can be obtained without installing additional soundproofing devices.
The features and advantages of the present invention will be more apparent from the following detailed description in conjunction with the accompanying drawings, in which:
The assembly unit for buildings and its fabrication method according to an exemplary embodiment of the present invention will now be described with reference to the accompanying drawings.
In brief,
As shown in the drawings, a flat panel type assembly unit 100 is provided in a state that a plurality of metal wires 120 are insertedly positioned in the interior of an expanded synthetic resin 110 along a lengthwise direction of the expanded synthetic resin 110. Each metal wire 120 is bent in a zigzag manner (See
The assembly unit for buildings may be formed by using a single expanded synthetic resin or a plurality of expanded synthetic resins.
With reference to
In this case, as shown in
The assembly unit 100 for buildings may be provided with a different size according to requirements at a construction site, and such single units as shown in
The expanded synthetic resins 110 may be made of one selected from the group consisting of flame-resistant expandable polystyrene (ESP), self-extinguishable expandable polystyrene and expandable polypropylene (EPP).
The flame-resistant expandable polystyrene is obtained by adding 5˜10 wt % of isopentane as a foaming agent and 10˜15 wt % of magnesium hydroxide (Mg(OH)2) as a flame retardant to 75˜85 wt % of polystyrene.
When polystyrene used is less than 75 wt %, durability would be degraded, and when polystyrene used is more than 85 wt %, expandability and flame retardancy would be degraded. Thus, polystyrene used should preferably be within the range of about 75˜85 wt %.
When isopentane used is less than 5 wt %, expandability would be degraded, but when more than 10 wt %, durability and flame retardancy would be degraded. Thus, isopentane used should preferably be within the range of about 5˜10 wt %.
When magnesium hydroxide (Mg(OH)2) used is less than 10 wt %, flame retardancy would be degraded, while when it is more than 15 wt %, durability and expandability would be degraded. Thus, magnesium hydroxide used should preferably be within the range of about 10˜15 wt %.
The self-extinguishable expandable polystyrene is obtained by adding 6˜15 wt % of isopentane as a foaming agent and 4˜5 wt % of carbon dioxide (CO2) to 80˜90 wt % of polystyrene.
When polystyrene used is less than 80 wt %, durability would be degraded, and when polystyrene used is more than 90 wt %, expandability and self-extinguishability would be degraded. Thus, polystyrene is preferably used within the range of about 80˜90 wt %.
When isopentane used is by less than 5 wt %, expandability would be degraded, while when it is more than 10 wt %, durability and self-extinguishability would be degraded. Thus, isopentane used should preferably be within the range of about 5˜10 wt %.
When carbon dioxide (CO2) used is less than 4 wt %, self-extinguishability would be degraded, while when it is more than 5 wt %, durability and expandability would be degraded. Thus, carbon dioxide used should preferably be within the range of about 4˜5 wt %.
The expandable polypropylene is obtained by adding 8˜12 wt % of isopentane as a foaming agent to 88˜92 wt % of polypropylene having a melting point (Tm) of 162.65° C. and density of 0.90 g/cm3.
When polypropylene used is less than 88 wt %, durability of expandable polypropylene would be degraded, and when it is more than 92 wt %, foaming does not occur well. Thus, polypropylene used should preferably be within the range of 88˜92 wt % with respect to the foaming agent.
Isopentane is used in connection with a mixture rate of polypropylene. When isopentane used is less than 8 wt %, expandability would be degraded, and when it is more than 12 wt %, durability of expandable polypropylene would be degraded. Thus, the foaming agent used should preferably be within the range of about 88˜92 wt %.
As shown in
As for the assembly unit 100 for buildings according to the present invention as shown in
The composition of components in the respective surface-treated layers, as shown in
A surface-treated first layer 141 is formed by coating a first mixture, which has been prepared by adding 6˜13 wt % of SiO2, 0.1˜0.8 wt % of Al2O3, 0.01˜0.08 wt % of Fe2O3, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K2O, 0.005˜0.05 wt % of TiO2, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO3 to 75.366˜90.772 wt % of silica sand of 0.1˜1.5 mm, on the surface of the expanded synthetic resin 110 and also on the surface of the metal wire mesh 130.
A surface-treated second layer 142 is formed by coating a second mixture, which has been prepared by adding 10˜20 wt % of SiO2, 0.3˜0.9 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K2O, 0.005˜0.06 wt % of TiO2, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na2O, 0.001˜0.007 wt % of ZrO2, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO3 to 66.218˜84.557 wt % of silica sand of 0.1 mm˜1.5 mm, on the first layer 141.
A surface-treated third layer 143 is formed by coating a third mixture, which has been prepared by adding 17˜25 wt % of SiO2, 0.2˜0.15 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K2O, 0.01˜0.07 wt % of TiO2, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO3 to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, on the second layer 142.
In detail, an arch type assembly unit 100′ is provided with one or more metal wires 120 bent in a zigzag manner and insertedly positioned within the expanded synthetic resin 110.
A certain height of the bent portions 121 of the metal wires 120 protrudes from front and rear surfaces of the expanded synthetic resin 110. Arch type metal wire mesh 130, corresponding to the area of the expanded synthetic resin 110, are welded and fixed to ends of the protruded bent portions 121 of the metal wires 120 in such a state that the arch type metal wire mesh 130 are separated by a certain interval from the front and rear surfaces of the expanded synthetic resin 110 with the protruded bent portions 121.
The arch type assembly unit 100′ may be formed by using a plurality of expanded synthetic resins 110 each having the bent metal wire 120, and in this case, the expanded synthetic resins 110 can be arranged side by side and assembled.
The arch type assembly unit 100′ may be used for the arch type structure of a building's door, window, ceiling, etc.
The flat panel as shown in
The assembly unit for buildings according to the present invention can be also fabricated as a structure such as a pillar or a beam in addition to the panels as shown in
As shown in
In this case, an iron beam may be introduced into the combined rectangular pillar 200 to enhance the strength, and in this case, an insertion hole 250 for inserting the iron beam vertically is formed at the center of the expanded synthetic resin 210 and an H-shaped beam (F) as shown in
Thereafter, cement mixture layers 241 to 243 as described in
A circular pillar 200′ as shown in
In this case, an iron beam may be introduced into the combined circular pillar 200′ to enhance the strength, and in this case, an insertion hole 250 for inserting the iron beam vertically is formed at the center of the expanded synthetic resin 210 and an H-shaped beam (F) as shown in
Thereafter, cement mixture layers 241 to 243 as described in
In the present invention, preferably, as a material of the metal wires 120 and 220 and the metal wire mesh 130 and 230, soft steel obtained by adding 0.12˜0.25% of carbon to iron used as steel of a general steel frame structure that has high strength and can withstand considerable deformation and damage, may be used to reduce the risk of brittle failure that occurs when iron is suddenly damaged by a slight deformation due to an external force.
A method for fabricating the assembly unit for buildings according to an embodiment of the present invention is described.
In order to fabricate the assembly unit for buildings according to an embodiment of the present invention, first, a metal wire 120 of a certain length as shown in
In the state that the metal wire 120 is fixed within the mold, the expanded synthetic resin 110 is molded to integrate the expanded synthetic resin 110 and the internally bent metal wire 120. In this case, the expanded synthetic resin 110 is molded such that a certain length of the bent portions 121 of the metal wire 120 are exposed from the front and rear surfaces of the expanded synthetic resin 110.
When a single metal wire 120 is inserted in the expanded synthetic resin 110 in order to fabricate the afore-mentioned arch type frame panel, a plurality of expanded synthetic resins 110 each including the metal wire 120 is prepared by performing the process as described above and placed side by side in a lengthwise direction. And then, the sides of the plurality of expanded synthetic resins 110 are attached to integrate the expanded synthetic resins 110 (S350).
Next, the metal wire mesh 130, which are the same size as the area of the front and rear surfaces of the expanded synthetic resin 110, are formed (S400), and then mounted on the front and rear surfaces of the expanded synthetic resin 110 (S500).
In this case, the metal wire meshes 130 are formed by welding metal wire horizontally and vertically in a checkered pattern.
In mounting the metal wire meshes 130 to the front and rear surfaces of the expanded synthetic resin 110, as described above, the bent portions 121 of the metal wire 120 exposed from the front and rear surfaces of the expanded synthetic resin 110 and portions of the metal wire meshes 130 are weld to combine the integrated expanded synthetic resin 110 and the metal wire mesh 130.
A method for treating the surface of the assembly unit for buildings according to an embodiment of the present invention is described.
After forming a certain structure by assembling the assembly units for buildings fabricated as described above, a first mixture, which has been prepared by adding 6˜13 wt % of SiO2, 0.1˜0.8 wt % of Al2O3, 0.01˜0.08 wt % of Fe2O3, 3˜10 wt % of CaO, 0.005˜0.03 wt % of K2O, 0.005˜0.05 wt % of TiO2, 0.05˜0.3 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.005˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.05˜0.3 wt % of SO3 to 75.366˜90.722 wt % of silica sand of 0.1˜1.5 mm, first coats the both or one of the front and rear surfaces of the expanded synthetic resin and also on the surface of the metal wire mesh and then is cured, for a surface treatment.
After curing the first coating, a second mixture, which has been prepared by adding 10˜20 wt % of SiO2, 0.3˜0.9 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 5˜12 wt % of CaO, 0.005˜0.07 wt % of K2O, 0.005˜0.06 wt % of TiO2, 0.1˜0.5 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.08 wt % of Na2O, 0.001˜0.007 wt % of ZrO2, 0.001˜0.007 wt % of SrO, and 0.01˜0.05 wt % of SO3 to 66.21˜884.557 wt % of silica sand of 0.1˜1.5 mm, secondly coats the cured first coating (s), and is then cured.
After curing the second coated surface, a third mixture, which has been prepared by adding 17˜25 wt % of SiO2, 0.2˜0.15 wt % of Al2O3, 0.01˜0.1 wt % of Fe2O3, 8˜15 wt % of CaO, 0.01˜0.07 wt % of K2O, 0.01˜0.07 wt % of TiO2, 0.1˜0.6 wt % of MgO, 0.001˜0.008 wt % of MnO, 0.01˜0.05 wt % of Na2O, 0.001˜0.008 wt % of ZrO2, 0.001˜0.008 wt % of SrO, and 0.1˜0.7 wt % of SO3 to 58.236˜74.557 wt % of silica sand of 0.1˜1.5 mm, thirdly coats the cured secondly coating, and is then cured.
The substantial mixture ratios with respect to the first to third coatings of the mixtures will now be described through embodiments.
A mixture obtained by adding 6 kg of SiO2, 0.1 kg of Al2O3, 0.01 kg of Fe2O3, 3 kg of CaO, 0.005 kg of K2O, 0.005 kg of TiO2, 0.05 kg of MgO, 0.001 kg of MnO, 0.005 kg of Na2O, 0.001 kg of ZrO2, 0.001 kg of SrO, and 0.05 kg of SO3 to 90.772 kg of silica sand of 0.5 mm is used for the first coat.
A mixture obtained by adding 10 Kg of SiO2, 0.3 kg of Al2O3, 0.01 kg of Fe2O3, 5 kg of CaO, 0.005 kg of K2O, 0.005 kg of TiO2, 0.1 kg of MgO, 0.001 kg of MnO, 0.01 kg of Na2O, 0.001 kg of ZrO2, 0.001 kg of SrO, and 0.01 kg of SO3 to 84.557 kg of silica sand of 1.0 mm is used for the second coat.
A mixture obtained by adding 17 kg of SiO2, 0.2 kg of Al2O3, 0.01 kg of Fe2O3, 8 kg of CaO, 0.01 kg of K2O, 0.01 kg of TiO2, 0.1 kg of MgO, 0.001 kg of MnO, 0.01 kg of Na2O, 0.001 kg of ZrO2, 0.001 kg of SrO, and 0.1 kg of SO3 to 74.557 kg of silica sand of 1.5 mm is used for the third coat.
The operational effects of the assembly unit for buildings according to the present invention will now be described in detail.
The assembly unit 100 fabricated through the above-described processes can replace the existing the reinforced concrete structures. First, a foundation work (ground concrete work) for a construction work is performed; that is, the foundation is dug, and a basic concrete basement floor is cast. Thereafter, the frame panels are welded and combined to form the structure of the inner and outer walls of the building.
That is, the frame panels including the plurality of expanded synthetic resins 110 are combined by welding the metal wires 120 according to the area of a wall, etc., desired to be formed.
In the case of constructing a dual-layered structure, the frame panel 100 used for a structure serving as an interlayer flat slab preferably has a thickness larger by 1.5 to 2 times that of the frame panel 100 used for forming the outer and inner walls.
In addition, in the case of a building having an arch type structure such as a blind in terms of consideration of an aesthetical appearance in front of the building such as a door or a window, the arch type structure can also be formed by using the frame panel 100 as shown in
After the framework of the building is constructed by using the frame panel 100, a finishing material such as mortar is sprayed (jetted) to finish the exterior of the frame panel 100, without casting concrete or without using a stiffener, and thereafter, tiles or stones are attached to the interior of the building to complete the construction work.
In this case, the finishing material such as mortar is, preferably, sprayed such that the bent portions 121 of the metal wire 120 exposed from the expanded synthetic resin 100 of the frame panel 100 cannot be exposed from the finishing material such that the metal wire mesh 130 are completely buried.
Thus, compared with the conventional art in which the materials such as reinforced concrete, etc., are used to form a structure, the assembly unit 100 for buildings according to the present invention is superior in that the assembly unit is quite light, the materials can be easily carried, and the construction duration can be shortened considerably by omitting the sequential processes of making a concrete form, casting concrete, and curing the concreted surface.
In addition, because the weight of the frame panel 100 is light, the stability of a worker can be secured, and because the frame panel 100 is simply combined through welding, the surrounding environment of the construction site will not be degraded due to casting of concrete and curing of concrete surfaces.
Further, when the frame panel 100 filled with the expanded synthetic resin 110 is applied to a building, good soundproofing can be obtained without installing additional soundproofing.
It should be understood that the embodiment of the present invention as described may be modified in many ways. Such modifications are not to be regarded as departure from the spirit and scope of the invention, and all such modifications, as would be obvious to one skilled in the art, are intended to be included within the scope of the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2007-0031324 | Mar 2007 | KR | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/KR2008/001715 | 3/27/2008 | WO | 00 | 3/17/2011 |
