Note: Descriptions are shown in the official language in which they were submitted.
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INSULATED WALL MODULE
DESCRIPTION OF THE INVENTION
1. Technical Field
This invention: a wall module of superior insulation properties for passive
buildings, a technique of
manufacture of a product provided with all needed installations, through
application of the
appropriate technological process, easy to install on a building site ¨
encompasses the
technological domains marked as E04B 2/58, E04C 1/00 and E04C 2/00 according
to the
International Patent Classification.
2. Technical Problem
Professionals continuously endeavor to achieve as minimum as possible
consumption of material
and time and as low as possible building costs per surface area unit of
structures in combination
with the optimum characteristics of structures and this has been a constant
technical challenge in
the technological field in question.
It is a well known fact that the price, quality and characteristics of a
structure are mostly
conditioned by the technical design of walls, therefore by their structure,
therefore, methods have
been developed to produce walls as finished structures, to the maximum
possible extent and to
find options for their as economical as possible installation at the building
site. Naturally, the
success of finding the above indicated technical solution is predominantly
conditioned by the
successful technical design of the wall and the manufacturing technique as
well as installation
methods-used-in-the-building-eonstruGtion-operations,
The technical problem resolved in the subject invention consists of the
definition of such wall
structure and of the application of such materials and making and building
techniques, to achieve
excellent insulation properties of the wall needed for the construction of
passive buildings with at
the same time meeting all the requirements of the professional building
practice and the
regulations with respect to the strength and the statics of walls and of the
entire building. It would
be preferable here to make sure also that the appropriate technological
process is used such that
the finished wall can be made in factory complete with ceramic tiles and
parquet flooring, with all
needed installations, all openings including door and window openings. The
simple and fast
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installation of a building on a building site with a low labor cost will
reduce significantly building
costs per surface area unit of the building.
In order to make sure that passive house standards are fulfilled, this has
been confirmed with the
"Blower ¨ Door ¨ Test", all external elements of the building except glazed
surfaces should have
such thermal insulation for the heat penetration coefficient U not to exceed
0.15 W/(m2K),
whereby the needed thermal energy does not exceed 15 kWh/m2.
The prerequisite for the completion of a passive house is the technical design
of the entire
envelope of the building with thermal insulation of the appropriate quality,
fully compact, i.e.,
almost hermetically closed building envelope. This means that edges, angles,
joining points and
openings must be designed in such manner that as consequence all thermal
bridges are
eliminated to prevent the loss of valuable heat through joints and various
openings.
This means that high and demanding standards will be set for the technical
design of walls as
structure components that have a prevailing impact on the resulting excellent
insulation properties
of individual sections or the building in entirety, achieved thanks to the
quality of used materials,
which, accompanied by adequate performance, allow the achievement of
characteristics specific
to passive houses.
It is preferable for the building walls to be made as a light load bearing
steel structure filled with
light material of excellent insulation properties, polyurethane (PIR) a fire-
retardant, and for the
walls to be of the appropriate thickness and of appropriate rectangular
dimensions (one-floor
elevation): higher than 2 m and of the appropriate width.
3. State of the Art
Historically, people have continuously endeavored to achieve as low as
possible consumption of
materials and time in combination with as low as possible building cost per
surface area unit of a
structure, with the optimum characteristics of the structure, mostly with
respect to insulation
properties which guarantee the lowest possible consumption of heating sources
per square meter
of residential surface, which includes: solid materials, gas, heating oil or
electricity.
A possible reduction of the building cost depends directly on the wall
structure that requires the
adequate consumption of materials, and it depends in particular on the extent
to which the wall
can be factory-built and on the extent of the remaining work that needs to be
done at the building
site.
Lately, the focus has been put on efforts to achieve such insulation
properties of a building for the
needed heating energy value not to exceed 15 kWh/m2 per year, which is a vital
feature of
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structures called passive houses. Studies and works have been done for over
two decades now in
the area of passive houses and it is clear that in order for the passive house
to be completed
some high and demanding standards need to be met in terms of the quality of
components of the
house. Therefore, all external elements of the house, except glazed surfaces,
need to have such
thermal insulation for the heat penetration coefficient U not to be higher
than 0.15 W/(m2K).
The passive house is a result of a low-energy house development cycle (NEK).
The passive
house consumes up to 80% less energy compared to a low-energy house and up to
90% less
energy compared to conventional building structures.
The uncontrolled exchange of the external and internal air must be prevented
in passive houses,
which can be achieved through excellent thermal insulation and a compact
structure of individual
components and of the entire structure.
This means that outside surfaces of a building must allow the full sealing of
its insulation envelope
for them to form jointly a sort of a wind-tight surface. In addition, joining
points of all structural
elements and utility channels must be made carefully to ensure the needed wind
tight property is
achieved. Edges, angles, joints and openings must be done properly to avoid
thermal bridges.
Structures performed according to such quality standards not only prevent
draught and the loss of
energy, but the reduced penetration of damp into structures reduces
substantially the risk of
damage on the building's structural elements.
Therefore, the design and work on a passive house for builders is a much more
complex task
than the design and work on, in terms of dimensions and functions, an
equivalent traditional
building.
The thickness of the passive house insulation should be at least 55 to 60 cm
in combination with
the placement of triple glazed windows and doors of appropriate thermal
insulation properties.
-The'llower __ - Door - Test" is used-to-check-whether-a-structure-meets-
the-passive-house-
building standards. All external elements of the building, except glazed
surfaces need to have
such thermal insulation for the heat penetration coefficient U not to exceed
0.15 W/(m2K).
The state of the art, in terms of achieving excellent insulation properties of
buildings, has given
some building techniques that use light wall elements.
Wall elements are mostly made of expanded polystyrene. Examples of these
techniques and their
resulting structures have been published in US5,353,562, US4,823,534 and US
5,617,686.
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EP 0 727 535 Al is the partition wall building technique that involves the use
of a large number of
posts and steel elements, securing the position of main surface materials on
both sides of the
element with the noise insulating material and hard gypsum panels as
reinforcement for the
principal external surfaces, making a fireproof wall structure.
US 5,765,333 describes the system of building using posts and panels that are
joined such that
the post is placed on the floor, a solid foam panel, consisting of one or
several glued layers of
solid foam shaped to fit the post placed next to the beam and joined with the
beam and the floor,
thereafter the following post is placed and joined with the same panel etc.
Prefabricated strips
may be placed on the surface of panels, to join gypsum panels on the inside of
the wall structure,
or as a fixing element on the outside.
There are several types of bearing wall structures mostly made at the passive
house building site
but the quality of the wall fill, from the technical and technological aspect,
is lower.
There are also modules, US2010242394(A1) and W02010111945 (Al), that are
somewhat
similar to the subject invention but different in terms of several essential
properties.
4. Essence of the invention
The importance of the invention is in its technical design that resolves the
indicated technical
problem by defining the load-bearing steel structure of the wall with all the
appertaining
components and all needed installations and openings for a specific structure
intended for a
specific purpose, of specified dimensions and location, of the specific layout
of premises, after the
completion of appropriate calculations, according to well known methods, and
in compliance with
the principal requirements set by the building regulations, such as pressure
strength, earthquake,
wind resistance and fire safety properties, which in the end allows in terms
of technology, the
development of complete walls, factory made, simple installation of these
walls on the building
site with the characteristics and qualities in compliance with the criteria
set to meet passive house
standards.
Such a defined steel structure consist of elements of specified shapes and
dimensions, in general
of C elements, horizontal 1.1 and vertical 1.2, C elements made of steel metal
sheathing of the
appropriate thickness and appropriately joined, according to the established
work method, with in
the middle additional steel elements for reinforcement 8.1., as suitable, for
additional strength,
according to calculations, and in addition to horizontal 1.1 and vertical 1.2
C elements.
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The suitable wall fasteners or their elements are fixed inside horizontal 1.1
and vertical 1.2 C
elements, according to calculations done in compliance with all relevant
building practice
requirements and regulations, to fasten walls or their segments horizontally
2.1 and vertically 2.2
with fasteners.
Horizontal and vertical wall fasteners consist of a clamping screw, with a
body 3.2 and a head 5.1,
of a fastener cylinder 3.1 with a housing for the C element and a nut 3.3 with
a housing for the C
element.
The fastener cylinder 3.1 with a housing and a nut 3.3 with a housing are
placed on the C element
in a position, as allowed by the internal surface 4.1 at the bottom of the C
element and two
internal side surfaces 4.2 of the C element such that neither the fastener
cylinder 3.1 nor the nut
3.2 ever protrude beyond the volume of the C element and so that they are
always at a distance D
from the edge 3.4 of the C element -fastening the wall either horizontally or
vertically.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the
housing, are placed
on the C element, as described above, laid in the direction of the axis 4.3 of
the C element, and
as a rule placed in the corner to lean against and be fixed on the internal
surface 4.1 at the bottom
of the C element and on the appropriate internal side surface 4.2 of the C
element, for better and
more compact joining of elements.
Such a developed steel structure of a wall or of its segments is of a specific
thickness 2.4, which
in compliance with calculations is sufficient for any requirements set with
respect to a specific
building. The needed number of suitably shaped internal 1.3 and external 1.4
spacers are placed
and fixed on appropriate points of horizontal 1.1 and vertical 1.2 C elements.
=The internal 1.3 and external 1.4 spacers are made
____________________________ of materials ofdequate thermal insulation
properties to eliminate thermal bridges between the outside and inside wall
surface.
The internal 8.2 and external 8.3 lining is placed on the internal 1.3 and
external 1.4 spacers, in
which way a space is left between the internal 8.2 and external 8.3 lining to
inject insulation fill 8.4
thereby obtaining the total thickness 2.5 of the wall or of its segments of
such dimensions that
depend on the intended use of the building premises and the set requirements,
which may be
approximately 200 - 400 mm, most frequently approximately 300 mm.
Holes are drilled on the internal 8.2 and external 8.3 lining at such position
to match the internal
1.3 and external 1.4 spacers.
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The wall or segment steel structure made in the above mentioned way, complete
with spacers,
fasteners and final lining, of the specified external volume, dimensions and
the surface, for
example of 36 m2, is placed in the frame of the matching dimensions and the
appropriate
pressurized (for example 3 bar) injection press is used to inject the suitable
insulation fill, most
frequently expanding polyurethane, which expands spontaneously and squeezes
the air out
hermetically filling every inch of the space between two end panels and
between boundary
surfaces of the steel wall structure or of the wall segment, formed by
appropriate elements, mostly
horizontal 1.1 and vertical 1.2 C elements.
In this way the structure of the wall is completely compact ensuring excellent
insulation properties
with the heat penetration coefficient U not higher than 0.15 W/(m2K ).
A module is the usual word used for a wall structure made according to the
above specified
method by using a press, either for complete walls or their segments. Modules,
in general, are of
a rectangular shape usually of the total surface area of 36 m2, 3 x 12 m in
height and width,
thereby meeting practically all the requirements encountered in practice.
If all such modules, i.e., all wall elements are factory-made, with all
windows, doors, utility
penetrations/channels and/or other additional elements installed in the
production facility, one can
make in advance the entire structure before it is brought to the building
site, which results in a
very flexible building concept with additionally reduced building costs.
These wall modules, completely factory-made in the described manner, are then
installed within
the building construction process, on the building site such that they are
joined horizontally and
vertically with fasteners.
After the placement of the lower bearing module 10.1 of the wall on the
foundations prepared in
advance, the floor module 10.3 of the wall is placed and thereafter the upper
bearing module 10.2
of the wall and partition walls, upper 10.4 and lower 10.5.
5. Brief description of the drawings
Figure la Essential Steel Structures
Position 1.1: Horizontal C element;
Position 1.2: Vertical C element;
Position 1.3: Internal spacer;
Position 1.4: External spacer;
Figure lb Examples of parts of the made steel structure seqment
Figure 2a Steel structure with fasteners
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Position 2.1: A part of the fastener for horizontal fastening of walls or
their segments;
Position 2.2: A part of the fastener for vertical fastening of walls or their
segments;
Position 2.3: Channels for the installation of pipes and utilities;
Position 2.4: Thickness of the steel wall structure;
Position 2.5: Total thickness of the finished wall
Position 2.6: Channels for clamping screws;
Figure 2b Examples of developed steel structures with fasteners
Figure 3. Wall or wall segment fastener assemblies
Position 3.1: The fastener cylinder with the housing to be fixed to the C
element;
Position 3.2: Clamping screw;
Position 3.3: The fastener's nut with the housing to be fixed to the C
element;
Position 3.4: The edge of the C element;
Position L: The total length of the C element;
Position D: The distance of the fastener, the cylinder or the nut from the
edge of the C
element;
Position W: The distance between the axes of two C elements with wall or wall
segment
fasteners;
Figure 4. The position of wall fasteners fixed to the C element
Position 4.1: The internal surface of the bottom of the C element;
Position 4.2: Internal side surfaces of C elements;
Position 4.3: The axis of the C element;
Figure 5. The assembly of the clamping screw and the fastener cylinder with
the housing to be
fixed to be C element
Position 5.1: The head of the clamping screw;
Figure 6. The assembly of the clamping screw and the fastener nut with the
housing to be fixed to
th-e-C-elem-ent
Figure 7. Examples of installed fasteners for vertical and horizontal
fastening of walls or their
segments
Figure 8. Essential wall components
Position 8.1: Steel structure elements, C elements and reinforcements;
Position 8.2: Internal lining;
Position 8.3: External lining;
Position 8.4: Insulation fill;
Figure 9. Cross section of the wall
Position 9.1: Internal support of the facade;
Position 9.2: External support of the facade;
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Figure 10. Examples of joined wall segments
Position 10.1: Lower load-bearing module of the wall;
Position 10.2: Upper load bearing module of the wall;
Position 10.3: Floor module of the wall;
Position 10.4: Upper partition wall;
Position 10.5: Lower partition wall;
6. Description of one mode for carrying out of the invention
The subject invention has been developed such that the appropriate calculation
has been done,
according to the known and established method, in compliance with all the
essential requirements
defined in building regulations, such as pressure strength, resistance to
earthquakes, wind and
fire safety, relating to a specified structure intended for a specified
purpose, with specified
dimensions and the location, the layout of premises; a load bearing steel
structure of the wall has
been defined in such manner with all components and all channels and openings
needed for
installation of plumbing and other installation elements, allowing the
application of the technology
of completely factory-built walls, easy to install on the building site
fulfilling all the criteria of
passive house building standards.
Such a defined steel structure consists of elements of specified shapes and
dimensions, mostly C
elements, horizontal 1.1 and vertical 1.2 C elements made of steel sheathing
of the appropriate
thickness and joined appropriately according to the well-known method, with
additional steel
reinforcement elements 8.1. between them, as needed, for additional strength,
according to
calculations.
In accordance with calculations made in compliance with all relevant rules of
the building practice
requirements and regulations, suitable wall or wall segment fastening
mechanisms are fixed
inside horizontal 1.1 and vertical 1.2 C elements, for horizontal 2.1 and
vertical 2.2 tightening and
joining of walls or their segments.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the
housing are placed on
the C element inside the space defined by the internal surface 4.1 of the
bottom of the C element
and two internal side surfaces 4.2 of the C element, such that neither the
fastener cylinder 3.1 nor
the fastener nut 3.2 ever protrude beyond the volume of the C element but they
are at the
distance D from the edge 3.4 of the C element whether used for vertical or
horizontal tightening.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the
housing are placed on
the C element as indicated above, laid in the direction of the axis 4.3 of the
C element, located in
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general in the corner and fixed appropriately to the internal surface 4.1 at
the bottom of the C
element and the respective internal side surface 4.2 of the C element, to give
more strength to the
joined segment.
Such a developed steel structure of the wall or of its segments is of the
specified thickness 2.4,
sufficient according to the calculation for a specific building. The
appropriate number of suitably
shaped internal 1.3 and external 1.4 spacers are placed and fixed at the
specified points
horizontally 1.1 and vertically 1.2 on the C elements.
Internal 1.3 and external 1.4 spacers are made of such materials that are of
appropriate thermal
insulation properties to eliminate thermal bridges between external and
internal surfaces of walls.
The internal 8.2 and external 83 linings are placed and fixed onto the
internal 1.3 and external 1.4
spacers, in which way the space is left between the internal 8.2 and external
8.3 lining in which
the insulation fill is injected 8.4 to make up the total thickness 2.5 of the
wall or its segments,
whose dimensions depend on the intended use of the building and the
corresponding
requirements, which most frequently may be up to 300 mm.
Holes are bored on the internal 8.2 and external 8.3 lining to match the
location of the internal 1.3
and external 1.4 spacers.
The steel structure of the wall or of its segment made as described above,
complete with spacers,
fastening mechanisms and final lining elements, of the specified outside
volume and surfaces, for
example of 36 m2, is placed in the frame of the appropriate dimensions and the
appropriate, for
example, 3-bar, injection press technique is applied to inject insulation
fill, most frequently
expanded polyurethane, which expands spontaneously while the pressure squeezes
out the air
hermetically sealing the space between placed final panels
____________________ and boun-dary¨gurfa-ces of th-e steel
structure of the wall or of its segments, consisting of elements, mostly,
horizontal 1.1 and vertical
1.2 C elements. Because of such compact wall structure the statics of the
steel structure is
improved for at least 30 c/o.
In such way a fully compact wall structure is achieved of excellent insulation
properties such that
the heat penetration coefficient U of the wall does not exceed 0.15 W/(m2K).
The module is the usual name for the wall structure obtained after the
application of the press
technique in the above mentioned way, both on complete walls or their
segments. Modules, in
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general are rectangular in shape, usually of the total surface area of 36 m2,
3 x 12 m in length and
width, meeting practically all requirements encountered in practice.
If all such modules, i.e., all wall elements are factory-made, with all
windows, doors, utility channel
and/or other additional elements installed in the production facility, one can
make in advance the
entire structure before it is brought to the building site, which results in a
very flexible building
concept and an additional reduction of building costs.
These wall modules, completely factory-made in the described manner, are then
installed within
the building construction process, on the building site such that they are
joined horizontally 7.1
and vertically 7.2 with fasteners.
After the placement of the lower bearing module 10.1 of the wall on the
foundations prepared in
advance, the floor module 10.3 of the wall is placed and thereafter the upper
bearing module 10.2
of the wall and partition walls, upper 10.4 and lower 10.5.
Internal facade supports are then fixed onto the steel structure, as
necessary, followed by the
installation of external facade supports (9.2) lying-on-the external-lining
(62).
7. Industrial applicability of the invention
The subject invention can be applied in the construction industry and achieve
the highest possible
flexibility of building, beyond any comparison, with the radically reduced
building costs and time
schedules, which is a natural result of a process in which all modules, i.e.,
all wall elements are
factory built with all windows, doors, installation channels and/or other
additional equipment
installed in the production facility, which means that the entire structure
can be built in advance,
before it is transported to the building site.
In addition, the subject invention allows the building of walls of excellent
insulation properties of
the heat penetration coefficient U not higher than 0.15 W/(m2K ), whereby the
subject invention
may be relevant in current construction achievements in the building of
passive houses fulfilling
the parameters and characteristics in compliance with the strictest standards.
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