Manufacture and Method of Installing, Notably Construction Panels Formed in a Closed Mold

Abstract

The present invention concern the fabrication of panels (11) (12) in which the elements (2) are assembled by gussets (3) (13) during the preparation in the mold

Description

[0001] The present invention concerns in general the concept and the on site set-up of insulated, weather-proof panels for construction.

[0002] It is generally known that the fabrication of panels in molded form does not present particular difficulty as long as these panels are not made with the aid of expandable products, in this instance, vents for the degassing of air are required, allowing the excess air to be driven out by the expansion of the foaming agents, a delicate operation.

[0003] The linking of the panels between themselves, in the set-up process is extremely complex and requires the presence of grooves for mechanically linking two panels. It is also necessary to fill these grooves after building the elements on the construction site.

[0004] It is also common that the connection between the ground and the panels is generally realised by incorporating metallic inserts during fabrication of the concrete slab, or otherwise reserved areas, that specify the precise positioning that is not always respected, being seen to be outside of the rules of the art.

[0005] It is also known that panel erected this way allows linking to the upper part of the frame elements, but the stresses between the ground and the frame are transmitted only by the panel elements themselves. This technique does not permit guarantee against a lifting of the frame during unfavorable climatic conditions.

[0006] The present invention concerns the seamless manufacture of a panel as well as the placing of these, without having to resort to any grooves in order to guarantee a connection between the ground and the frame elements, within the rules of the art. The connection between panels also makes possible a later filling of the cavities.

[0007] The present invention is characterized by the manufacture of a panel in a mold dimensioned to contain the elements inserted in this molding:

[0008] 1) A sheet of wallboard (1) or other on the bottom of the mold .

[0009] 2) metal profiles (2) forming the frame of the panel (10) this frame (2) is assembled into the mold itself, with the aid of metal gussets (3) anchored by spot-welding or metallic screws (15), that approach avoids the handling of the profiles (2) previously carried out with difficulty.

[0010] 3) profiles (4) in synthetic materials for protection of the panel edges during set-up, these profiles simply laying on the metal profiles (3) maintaining the fiber plate (5) at a respectable distance.

[0011] 4) jackets (8) along each external side for the fine Installation of various piping.

[0012] 5) a sheet of wood-fibres (5) in this case, not bonded tightly is then placed on the synthetic profiles (4) thereby closing the frame of the panel before closing the mold and injecting the expandable products.

[0013] 6) the injection of expandable reactive products (9) which after polymerization, function to fill the cavity, completely bonding all the components Comprising the future panel. The panel, thereby becoming one part (contiguous) and very strong is removed from the mold.

[0014] The present invention is characterized by the fact that the plate is not air tight, allowing the evacuation of the excess air (6) while allowing the impregnation of part (7) of the thickness of the plate (5), by the expandable material (9). The panel presents a rough outside exterior for the future application of a polymeric cement surface coating, on the building site.

[0015] The present invention offers the advantage of equally fabricating straight (11) or angled (12) elements by following the same technique, the external profiles (2) of the future panel are positioned in the mold perpendicularly to the face of the panel and themselves assembled by the appropriate metal gussets (13). This avoids the need for angle beams for the panel set-up.

[0016] The panels obtained in this manner are entirely closed on all their edges, the longitudinal side is in the form of a U shape for connecting the panels.

[0017] The present invention relates to the method of using the panels. At the end of junction tube (16) are welded metal pieces (17) comprising a thread (22) and a face (21). This junction tube (16) is incorporated into the profiles (2) forming edges in the form of a U shape on the bottom side of the panels (17), the connection to the tube is fixed with expansion bolts (2), rendering the tube (16) and the masonry (24) solid without having reserved niches linked to the ground (foundation).

[0018] PVC tube (18) is positioned inside the junction tube (16), and is itself maintained by fitting in the surface (21) of metal pieces (17).

[0019] The second panel is also encased at the linking tube (16), and solidified by metal screw (25) crossing the profile (2) and the linking tube (16). This assembly thereby attaches the two panels to the ground.

[0020] The present invention is characterized by the chemical foam that links the panels together. The PVC tube (18) positioned inside the linked panels, has holes (20) well spread along it's length. allowing the distribution of foam product (9) on (into) the connecting assembly of the two panels. The injection is made at the upper part of the connecting tube (16) across drilled plate (17), expansion being controlled by the position of the nut (19) screwed onto the plate (17).

[0021] The present invention allows for a chemical mechanical connection between panels insensitive to weathering and stress. The injection to the interior of the tubes (18) can be made soon after the installation of the two panels or later without any problem.

[0022] The present invention assures a very strong link between the ground and the frame, made possible by the connecting tube (16) attached to the upper and lower pan by bolting onto the plates (17).

[0023] The present invention allows one to obtain an assembly of strong beams at each end of the panel, through the solid construction of the profiles (2) and the connecting tube (16) the beam for the angle (12) being of the same concept as the straight coupling beams (11).

THE FOLLOWING DRAWINGS SHOWS THE PRESENT INVENTION

[0024] FIG. 1 represents: vertical section (line) of the panel

[0025] FIG. 2 represents: horizontal section (line) of a right connected panel

[0026] FIG. 3 represents: vertical section (view) of the bottom of the panel

[0027] FIG. 4 represents: horizontal section (view) of angled panels

[0028] FIG. 5 represents: vertical section (view) of panel linked to ground and frame

[0029] FIG. 6 represents: the pour in place (view) of the panel components in the mold

[0030] FIG. 7 represents: frame fabrication-angled and straight

[0031] FIG. 8 represents: a section (view) of a panel type

Claims

1) The present invention concerns the factory fabrication of insulated, weather resistant panels by incorporating into the mold the (furnishings) materials for obtaining these said panels and notably the metallic profile assemblies (2) with gussets (3), (13) for the fabrication of panels joined at right angles. (11) or variable angles (12).

2) The present invention is characterised by the use of porous plates (5), to allow the evacuation of the excess air (6), of which the expandable material (9) penetrates only partly through the thickness of the porous plate thereby enabling the face not impregnated with the foam product to accept a future coating.

3) The present invention is characterized by the incorporation, during the preparation of the panel mold, jackets (8) for the future placement of different wiring after the installation of the panels on site.

4) The present invention is characterised by a tight sealed connection (26) between two panels, the link made weather resistant, by the injection of expandable product (9) inside a a special tube (13) having holes (20) well spread along the tube, allowing the uniform spread of the expandable product.

5) The present invention is characterized by the link between bottom part connected to the ground (24) and the upper part of the panel (27) attached solidly to the frame. The connecting profile (16) provided with plate (17) renders the panels solid to the ground and the frame.

6) The present invention is characterized by the absence of provisional niches being provided and before being subsequently filled, after the link between the panels and their attachment to the ground, through the presence of the junction tube (16) with which the connection to the ground is realized with the aid of pin (23) a foam or chemical sealant, avoiding all the complex reservations (set-up) THIS IS STILL UNINTELLIGIBLE AND NEEDS MORE WORK.

7) The present invention allows for a water tight seal (26), at the set-up of two panels or after the connection of the necessary panel assemblies at the construction site.