WO2008075114A1

WO2008075114A1 - Method for making building unit with reinforcing wire mesh and building unit

Info

Publication number: WO2008075114A1
Application number: PCT/HU2007/000109
Authority: WO
Inventors: Zoltán CSALLÓ
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-12-20
Filing date: 2007-11-21
Publication date: 2008-06-26
Anticipated expiration: 2009-06-20
Also published as: HU0600934D0; HUP0600934A2

Abstract

The subject of the invention are a method for making building unit with reinforcing wire mesh and a building unit made by this method. During one method the wire mesh (2) is fixed into the surface layer of the polystyrene panel (1) in such a manner, that the polystyrene panel (1) together with the wire mesh (2) laid on it is pushed through below a preheated rotating cylinder (4) and the wire mesh (2) is fixed into this melted layer of said panel. During another method the wire mesh (2) is fixed into the surface layer of the polystyrene panel (1) in such a manner, that the polystyrene panel (1) together with the wire mesh laid on it, is slightly pressed with a pre-heated profile (5) and the wire mesh (2) is fixed into this melted layer of said panel. Upon a further method a wire mesh (2) is located below and/or above the polystyrene pellets (6) placed in the working space (7), then with the help of the hot steam fed into the closed working space (7), the wire mesh (2) is fixed into the surface of the polystyrene panel (1). The building element is characterized in that a reinforce wire mesh is fixed into the surface layer of minimum one side of the polystyrene panel (1), forming the building element. The technical result consists in an obtainment of the building elements with a high degree of flexibility, which are adaptable ones for a construction of lightweight erections

Description

Method for making building unit with reinforcing wire mesh and building unit

The subject of the invention is a method for making building unit with reinforcing wire mesh and the building unit made by this method. This method is suitable for producing building units of proper rigidity, elongation at break, resistivity and high flexibility, suitable for building lightweight structures and paneling buildings.

Nowadays there is a great demand for making lightweight structures, which can be quickly, easily and cheaply set up and - after it has served the purpose - can be quickly, easily and cheaply dismantled. These can be well used in each situation, when a temporary building is needed, or such a building, that is meant to exist longer, but it is cost-effective to build, can be quickly built and no continuous, regular maintenance is needed afterwards. Such buildings are used on a building site as temporary structures on a staging area, for storing tools, as a toy structure for children, or as a garage. There are various materials used for building lightweight structures. Among these wood, plywood, cellulose-fiber, different metals, cementmortar reinforced with polypropylene fibers are the most common.

The P 84 02089 Hungarian patent application published on 28 May 1990 makes known a state of the art laminated insulating sheet for interior heat insulation of buildings. The essence of the solution is, that a stiffening sheet providing mechanical strength and smooth surface is stuck with adhesive material on at least one side of the nikecell polystyrene foam sheet applied as insulation. The smooth surface stiffening sheet can be applied to both sides of the insulating plastic foam sheet in one or two layers. Cardboard is preferably used as stiffening sheet and dispersion polymer resin as adhesive material. The heat insulating sheets according to the invention can be pre-fabricated for example in form 50x50 cm. When the ready sheets are fixed to the walls, one side should be provided with a layer of adhesive, and they must be joined without airgaps.

The P 04 00423 Hungarian patent application published on 28 November 2005 describes a method for creating surfaces with lightweight ornaments for facades and interior wall surfaces. During the method first the ornamental element is cut from the polystyrene board, then the external side of the ornament is provided with a flexible, stiffening and shell layer. After setting of the material a support profile is cut out of the element, which is fixed on the given wall surface with adhesives and plastic dubeling. The finished ornament is fixed on this with adhesives.

The drawbacks of the known materials are, that wood, plywood, cellulose fiber, possible metals - with the exception of aluminium — as well as cementmortar are heavy, so their transport and use for building is laborious. Commercially available prefabricated buildings made of wood can be bought either in finished form, already assembled, in this case it is difficult to deliver them, or they can be bought in disassembled condition, but then their assembly requires great expertise. Besides wood standing outdoors needs continuous, regular maintenance during the years. Aluminium is lightweight, does not require continuous maintenance, but it is very expensive. Polystyrene is lightweight, relatively cheap, does not need continuous maintenance, but it is statically not suitable in itself as outdoor building material, because its elongation at break is not sufficient to resist environmental effects the building is exposed to outdoors.

When working out the solution according to the invention we aimed to create a method, which makes possible the simple production of a lightweight, cheap building material of appropriate mechanical and static parameters. Furthermore we aimed at creating such a building element, which can resist sunshine, windload, snowload, furthermore it makes possible to make lightweight buildings and it does not need continuous maintenance outdoors. We aimed furthermore at ensuring, that the building element has static and mechanical parameters suitable for separating interior spaces.

We realized when working out the solution according to the invention, that in case a wire mesh is fixed to one, or both sides of the polystyrene or other plastic panel or profile of similar features, by melting the polystyrene board or profile applying low pressure, then the set aim can be achieved.

The invention is a method for making building unit with reinforcing wire mesh, during said method a reinforcing material of mesh structure is fixed on the surface of a panel or profile made of plastic raw material. The wire mesh is fixed in the surface layer of the polystyrene panel in such a way, that the polystyrene panel together with the wire mesh laid on it is pushed through below a preheated rotating cylinder, while the surface layer of the polystyrene panel melts, resulting from the heat, and the wire mesh is fixed into this melted layer.

Furthermore the invention is a method for making building unit with reinforcing wire mesh, during said method a reinforcing material of mesh structure is fixed on the surface of the panel or profile made of plastic raw material. The wire mesh is fixed into the surface layer of the polystyrene panel in such a way, that the polystyrene panel together with the wire mesh laid on it, is slightly pressed with a pre-heated profile, while the surface layer of the polystyrene panel melts resulting from the heat, and the wire mesh is fixed into this melted layer.

Furthermore the invention is a method for making building unit with reinforcing wire mesh, during said method simultaneously with the production process of the panel or profile made of plastic raw material, a reinforcing material of wire mesh structure is fixed on the surface of the building element. Below, and/or above the polystyrene pellets placed in the working space a wire mesh is located, then with the help of the hot steam fed into the closed working space, the wire mesh is fixed into the surface of the polystyrene panel.

In one preferred application of the method according to the invention the material of the plastic building element is an foamed thermoplastic of closed cell structure, containing gaseous bubbles, preferably polystyrene.

In another preferred application of the method according to the invention the density of the plastic building element is 5-50 kg/m³. In a further preferred application of the method according to the invention the material of the wire mesh is textile, metal, plastic, or metal fiber, preferably glass-fiber.

In a further preferred application of the method according to the invention the temperature applied during melting is 100-200⁰C, preferably 130⁰C.

In a further preferred application of the method according to the invention the period of melting depends on the density of the polystyrene panel and the required degree of shrinking.

Furthermore the invention is a building element produced by the above methods and into the surface layer of minimum one side of the polystyrene panel composing the building element a reinforcing wire mesh is fixed.

In a further preferred embodiment of the building element according to the invention a reinforcing wire mesh is fixed into the surface layers of both sides of the polystyrene panel composing the building element.

The solution according to the invention is set forth furthermore with the enclosed drawings:

The Fig 1 shows the starting step of one of the possible production methods of the building element according to the invention in side view.

The Fig 2 shows in side view an interim phase of the production process of the building element according to the invention showed in Fig 1.

The Fig 3 shows another possible production method of the building element according to the invention.

The Fig 4 shows a further possible production method of the building element according to the invention in side views.

The Fig 5 shows the building element according to the invention before the melting process in cross-section, with the wire mesh, in given case wire mesh made of glass fiber, placed on both surfaces of the polystyrene panel.

The Fig 6 shows the building element according to the invention after the melting process, in cross-section with the wire mesh melted into both surfaces of the polystyrene panel.

The Fig 7 shows the spatial view of the building element according to the invention, with the position of the individual layers.

The Fig 1 shows the starting step of one of the possible production methods of the building element according to the invention in side view. The polystyrene panel 1 of D thickness placed on the working surface 3 can be seen in the picture. The wire mesh 2 in given case made of glass fiber is placed on the surface of the polystyrene panel 1. The cylinder 4 placed above the working surface 3 is positioned in such a way, that the distance of the horizontal lower mantle of the cylinder 4 from the working surface 3 is D-Δd, where Δd is the degree of shrinking on one side resulting from heat treatment. Then after having heated the cylinder 4 to 100-200⁰C, preferably to 130°C, the cylinder 4 is rotated towards the direction marked by an arrow in the picture, and simultaneously the polystyrene panel 1 is pushed through below the cylinder 4 towards the direction marked by the arrow in the picture.

The Fig 2 shows in side view an interim phase of the production process of the building element according to the invention showed in Fig 1. It can be seen in the picture, that the polystyrene panel 1 pushed through below the cylinder 4 became thinner, of D-Δd thickness, resulting from the heat treatment, and on this part the wire mesh 2 made in given case of glass fiber is already fixed into the surface of the polystyrene panel 1. Whereas the thickness of the polystyrene panel 1 positioned before the cylinder 4 is the original D thickness.

The Fig 3 shows another possible production method of the building element according to the invention. This case melting of the wire meshes 2 into the surfaces of the polystyrene panel 1 is made simultaneously, with the help of profiles 5 heated to the proper temperature, by the small degree moving of the profiles 5 towards the direction shown in the picture.

The Fig 4 shows a further possible production method of the building element according to the invention in side views. This case the melting of the two wire meshes 2 takes place during the production of the polystyrene panel 1. The polystyrene pellets 6 are placed into a closed working space 7 in such a way, that the wire mesh 2 is placed on the bottom of the working space 7, the polystyrene pellets 6 come on top of this, then the other wire mesh 2 is laid on the polystyrene pellets 6. Then in the known way hot steam is blown into the working space 7, resulting in the expansion of polystyrene pellets 6, and so they fill in the closed working space 7, while both wire meshes 2 are fixed into the polystyrene panel 1 made this way. This case the wire meshes 2 are not directly fixed on the surface of the polystyrene panel 1.

The Fig 5 shows the building element according to the invention before the melting process in cross-section, with the wire mesh, in given case wire mesh made of glass fibre, placed on both surfaces of the polystyrene panel 1. Before the process on the surfaces of both sides of the polystyrene panel 1 of D thickness a wire mesh 2 can be found. It can be seen well in the picture, that in this case the wire meshes 2 are situated separately from the material of the polystyrene panel 1.

The Fig 6 shows the building element according to the invention after the melting process, in cross-section with the wire mesh 2 melted into both surfaces of the polystyrene panel 1. The state after the melting is shown in the picture, when one wire mesh 2 is melted into both sides of the polystyrene panel 1. The polystyrene panel 1 originally of D thickness becomes d thickness at the end of the process. In the picture it can be well seen, that in this case the wire meshes 2 are embedded into the material of the polystyrene panel 1, because during the process the surface of the polystyrene panel 1 melts a little, and the melted material envelopes the fibers of the wire mesh 2, which could be removed from the surface of the polystyrene panel 1 after the cooling phase by mechanical destruction only. The Fig 7 shows the spatial view of the building element according to the invention, with the position of the individual layers. On the opposite sides of the building element there is a wire mesh 2 each, with the polystyrene panel 1 in the middle.

During a preferable concrete application of the method according to the invention the polystyrene panel 1 of D thickness is laid on a horizontal working surface 3. Then the wire mesh 2 is placed on the surface of the polystyrene panel 1. The cylinder 4 placed above the working surface 3 is positioned in such a way, that the distance of the horizontal lower mantle of the cylinder 4 from the working surface 3 is D-(D-d)/2. Then after having heated the cylinder 4 to 100-200⁰C, preferably to 13O⁰C, the polystyrene panel 1 is pushed through below the cylinder 4 while the cylinder 4 is rotated at the same time. The surface of the polystyrene panel 1 melts to a small degree resulting from the heat effect, and the wire mesh 2 is embedded and simultaneously set into this melted layer. The thickness of that part of the polystyrene panel 1 of D thickness, which has already been in contact with the cylinder 4, becomes thickness of D-Δd = D-(D-d)/2, where Δd = (D-d)/2. After a few minutes of cooling time the polystyrene panel 1 is turned round, and the steps of the procedure just described are repeated on the other side of the polystyrene panel 1. Resulting from this procedure the polystyrene panel 1 becomes of d thickness, and the wire mesh 2 can be found fixed on both sides of the polystyrene panel 1.

With the help of the above procedure an ornamental surface can also be produced in such a way, that the required ornament is applied to the surface of the cylinder 4 with embossing (brick, stone, other markings) and during the above mentioned procedure the markings formed on the surface of the cylinder 4 appear on the polystyrene panel 1. The polystyrene panel 1 with ornament made this way has better static features as well besides being more sophisticated from aesthetic point of view as well. The aesthetic value of the polystyrene panel 1 can be further enhanced by the proper coloring of the embossment.

In another preferable realization of the solution according to the invention the wire mesh 2 is fixed to both sides of the polystyrene panel 1 simultaneously resulting from the heat effect by melting in such a way, that the polystyrene panel 1 containing a wire mesh 2 on its both surfaces is put between two profiles 5 heated upto 100-200⁰C, preferably upto 13O⁰C. In case the polystyrene panel 1 is produced as an ornamental element the required markings can be formed on the surface of the profiles 5 with embossing. By pressing the profiles 5 onto the polystyrene panel 1 the markings formed on the surface of the profiles 5 appear on the polystyrene panel 1. The ready ornamental element can be painted this case as well.

During the above described procedures a release foil is preferably laid on the wire mesh 2 laid on the surface of the polystyrene panel 1 before starting the melting to prevent sticking of the melted polystyrene to the cylinder 4, or to the profile 5. In given case sticking of the melted polystyrene to the cylinder 4 can be prevented by providing the surface of the cylinder 4 with a coating, a layer promoting the process of release (eg. oil, lubricant, non-stick etc.) Having finished the procedure the release foil can be easily removed and can be used again. In case of the above described two realizations melting and low degree pressure take place simultaneously: the surface of the polystyrene panel 1 melts, the wire mesh 2 sets into the melted polystyrene layer, and resulting from the melting and low degree pressure the thickness of the polystyrene panel 1 decreases from D to d.

In case of a further preferable realization of the solution according to the invention the two wire meshes 2 are not melted onto the ready polystyrene panel 1, but the two wire meshes 2 are melted during the production of the polystyrene panel 1 itself. In this case the polystyrene pellets 6 are placed in a closed working space 7 in such a way, that the wire mesh 2 is placed on the bottom of the working space 7, the polystyrene pellets 6 are placed above it, then the other wire mesh 2 is placed on top of the polystyrene pellets 6. Then in the known way hot steam is blown into the working space 7, resulting in the expansion of polystyrene pellets 6 and so they fill in the closed working space 7, while both wire meshes 2 are fixed into the polystyrene panel made this way. In this case the wire meshes 2 are not directly fixed on the surface of the polystyrene panel 1. In concrete application the material of the wire mesh is glass-fibre, rabitz mesh, textile, metal mesh, plastic mesh. The material of the release foil is paper, baking paper, industrial textiles, glass-fiber canvas, glass-fiber reinforced foil etc.

Other plastic base foam, PUR foam as well as a group of thermoplastics can be used as the material of the panel instead of polystyrene. So preferably every thermoplastic containing gas consistency bubbles, the density of which falls in the range 5-50 kg/m3. The denser the raw material is, the more treadproof (EPS 70 → EPS 200) is the ready building element.

During a concrete application of the method according to the invention melting and pressing take place simultaneously: the surface melts while being pressed. During the method melting is the essential point, pressure is of smaller degree, the polystyrene pellets melt resulting from the heat and envelope the wire mesh 2. So the surface of the polystyrene in contact with the warm cylinder becomes a thin plastic layer. If the material is denser, than the plastic layer is thicker. The fireproof feature can be ensured by proofing, or inflammable materials are used. In a preferable realization the material of the wire mesh 2 is plastic, in another case glass-fiber. A metal wire mesh can be applied as well, but in that case it must be instantly cooled at the end of the process to ensure safe fixing of metal wire mesh. The wire mesh can be: carbon fiber, textile fiber, aramide other plastic fiber (polystyrene panels can be reinforced by these fiber techniques.)

This solution can be applied as ornamental paneling. In this case the embossing of the pattern (eg. brick pattern) can take place with or without the mesh wire. Embossing the pattern can in itself result in reinforcing, but better results can be achieved together with the wire mesh. The embossing of the pattern can take place in such a way that the pattern is placed on the cylinder. Pressure is needed to produce the proper thickness only. Namely the polystyrene shrinks due to the heat, not due to the pressure. One must be careful, as too high temperature results in full shrinkage of polystyrene. In a preferable realization of the solution according to the invention during forming the pattern and form not only wire mesh and other materials can be melted. The foamed thermoplastic building element of closed cell structure, containing bubbles of gas consistency, preferably made of polystyrene according to the invention can be changed with melting itself, in given case with a hot mold into a shape and form, which is required during application. For example it is possible to create a star-shaped block from a block by melting. During the known processes manufacturers formed the material of the building element by swelling. Contrary to this during the process according to the invention it is melted into a specific mold and shrunk back.

The advantages of the solution according to the invention are the following: the polystyrene panel reinforced by wire mesh, made with such technology is lightweight, it is easy to build up various structures from it, can be well varied, cost-effective, no continuous, regular maintenance is needed even in case of outdoor location, at the same time it has such mechanical parameters, which make it possible to resist different outdoor exposures - such as the sunshine, windload, snowload, rain - still with satisfactory static features. The surface gained by this way is more robust, more resistant, more rigid, but more flexible at the same time.

A further advantage of the solution according to the invention is, that various surface patterns can be made on the building elements created this way, for example brick, -or stone markings, etc. Resulting from this the building elements can be installed on any surface, can be used for ornamental purposes as well. The building element according to the invention is suitable as tread-proof insulation as well.

Claims

CLAIMS:

1. Method for making building unit with reinforcing wire mesh, during said method a reinforcing material of mesh structure is fixed on the surface of a panel or profile made of plastic raw material, characterized by that, a wire mesh (2) is fixed into the surface layer of the polystyrene panel (1) in such a way, that the polystyrene panel (1) together with the wire mesh (2) laid on it is pushed through below a preheated rotating cylinder (4), while the surface layer of the polystyrene panel (1) melts, resulting from the heat, and the wire mesh (2) is fixed into this melted layer.

2. Method for making building unit with reinforcing wire mesh, during said method a reinforcing material of mesh structure is fixed on the surface of the panel or profile made of plastic raw material, characterized by that, the wire mesh (2) is fixed into the surface layer of the polystyrene panel (1) in such a way, that the polystyrene panel (1) together with the wire mesh (2) laid on it, is slightly pressed with a pre-heated profile (5), while the surface layer of the polystyrene panel (1) melts resulting from the heat, and the wire mesh (2) is fixed into this melted layer.

3. Method for making building unit with reinforcing wire mesh, during said method simultaneously with the production process of the panel or profile made of plastic raw material, a reinforcing material of wire mesh structure is fixed on the surface of the building element, characterized by that, below, and/or above the polystyrene pellets (6) placed in the working space (7), a wire mesh (2) is located, then with the help of the hot steam fed into the closed working space (7), the wire mesh (2) is fixed into the surface of the polystyrene panel (1).

4. Method according to any of claims 1-3, characterized by that, the material of the plastic building element (1) is a foamed thermoplastic of closed cell structure, containing gaseous bubbles, preferably polystyrene.

5. Method according to any of claims 1-4, characterized by that, the density of the plastic building element (1) is 5-50 kg/m³.

6. Method according to any of claims 1-5, characterized by that, the material of the wire mesh (2) is textile, metal, plastic, or metal fiber, preferably glass-fiber.

7. Method according to any of claims 1-6, characterized by that, the temperature applied during melting is 100-200⁰C, preferably 130°C.

8. Method according to any of claims 1-7, characterized by that, the period of melting depends on the density of the polystyrene panel (1) and the required degree of shrinking.

9. Building element, made primarily with a method according to claims 1-8, characterized by that, into the surface layer of minimum one side of the polystyrene panel (1) composing the building element a reinforcing wire mesh is fixed.

10. Building element according to claim 9 characterized by that, a reinforcing wire mesh (2) is fixed into the surface layers of both sides of the polystyrene panel (1) composing the building element.