U.S. patent application number 11/911042 was filed with the patent office on 2009-05-14 for core-insulated pre-fabricated wall piece with connector pins.
Invention is credited to Dirk Wetzel.
Application Number | 20090120026 11/911042 |
Document ID | / |
Family ID | 34717003 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090120026 |
Kind Code |
A1 |
Wetzel; Dirk |
May 14, 2009 |
Core-Insulated Pre-Fabricated Wall Piece With Connector Pins
Abstract
The invention relates to a pre-fabricated wall piece (1) for the
construction of buildings, comprising an inner wall (4) and an
outer wall (3) made from concrete, connected to each other by means
of reinforcements (2) and with a cavity (5) between both walls (3,
4) for subsequent filling with concrete. The inner side (6) of the
outside wall (3) facing the inner wall (4) further comprises a
thermal insulation layer (8) for reduction of the heat transfer
between the walls (3, 4). The pre-fabricated wall piece is
characterized in that the reinforcement (2) connecting the outer
wall (3) and the inner wall (4) comprises U-shaped connector pins
made from steel, retained by the web thereof in the outer wall (3),
and a lattice-beam reinforcement (9) that projects into the cavity
(5) from the inner side (7) of the inner wall (4) facing the outer
wall (3). Said pre-fabricated wall piece (1) has the advantage that
it has fewer heat bridges for a reduced heat transfer between the
inner wall and the outer wall (4, 3) and that it is simple and
economical to produce.
Inventors: |
Wetzel; Dirk; (Bingen,
DE) |
Correspondence
Address: |
MARK D. SARALINO (GENERAL);RENNER, OTTO, BOISSELLE & SKLAR, LLP
1621 EUCLID AVENUE, NINETEENTH FLOOR
CLEVELAND
OH
44115-2191
US
|
Family ID: |
34717003 |
Appl. No.: |
11/911042 |
Filed: |
April 8, 2006 |
PCT Filed: |
April 8, 2006 |
PCT NO: |
PCT/DE06/00622 |
371 Date: |
October 9, 2007 |
Current U.S.
Class: |
52/405.3 ;
52/407.1; 52/649.1 |
Current CPC
Class: |
E04B 2/8617 20130101;
E04B 1/161 20130101; E04B 1/7608 20130101; E04C 2/044 20130101 |
Class at
Publication: |
52/405.3 ;
52/407.1; 52/649.1 |
International
Class: |
E04B 1/80 20060101
E04B001/80 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 12, 2005 |
DE |
20 2005 005 924.2 |
Claims
1. A pre-fabricated wall piece for the construction of buildings,
comprising an inner wall and an outer wall made from concrete,
connected to each other by means of reinforcements and with a
cavity between both walls for subsequent filling with concrete,
where the inner side of the outside wall facing the inner wall
further comprises a thermal insulation layer, wherein the
reinforcement connecting the outer wall and the inner wall
comprises U-shaped connector pins made from steel, retained by the
web thereof in the outer wall, and a lattice-beam reinforcement
that projects into the cavity from the inner side of the inner wall
facing the outer wall.
2. A pre-fabricated wall piece according to claim 1, wherein the
lattice-beam reinforcement extends in the cavity all the way to the
thermal insulation layer.
3. A pre-fabricated wall piece according to claim 1, wherein at the
upper end of the outer wall, an uppermost row of connector pins is
provided as connecting reinforcement whose free ends project into
the space of a joint (20) with a ceiling element and that can be
connected with the ceiling element.
4. A pre-fabricated wall piece according to claim 1, wherein the
outer wall of the pre-fabricated wall piece is supported on a
foundation.
5. A pre-fabricated wall piece according to claim 1, wherein the
connector pins are made of non-rusting material like stainless
steel (V2A, V4A) or hot-galvanized steel.
6. A pre-fabricated wall piece according to claim 1, wherein the
lattice-beam reinforcement is made of steel without corrosion
protection.
Description
[0001] This invention relates to a pre-fabricated wall piece for
the construction of buildings, comprising an inner wall and an
outer wall made from concrete, connected to each other by means of
reinforcements and with a cavity between both walls for subsequent
filling with concrete, with the inner side of the outside wall
facing the inner wall further comprising a thermal insulation
layer.
[0002] It is known that for constructing walls of buildings in the
basement as well as the living areas, double-wall elements can be
used whose outer walls are connected to the inner walls with
lattice-beams and that comprise a core insulation consisting of
thermal insulation panels or insulation material applied in some
other manner. These pre-fabricated wall pieces have the advantage
that they can be produced at the factory as transportable parts and
independent of weather conditions. Such pre-fabricated wall pieces
can be made true to measure, are assembled at the construction
site, and are filled, without gaps, with concrete or similar
materials.
[0003] DE 198 23 387 describes a pre-fabricated wall piece where
the outer wall and the inner wall are connected by means of spaced
lattice beams. In order to provide thermal insulation, one or
several layers of a porous insulating coating made of polyurethane
foam are applied to the inner side of the outer wall. In order to
prevent air humidity from causing the lattice beams to rust through
over time, the beams are made from non-rusting material.
Pre-fabricated wall piece elements made in this manner have the
disadvantage that the lattice beams form massive heat bridges
between the inner and outer wall, thereby allowing significant heat
transfer.
[0004] The invention addresses this problem by proposing a
pre-fabricated wall piece that offers a reduced heat transfer
between the inner and outer wall due to fewer heat bridges, and is
simple and economical to produce while being able to support high
loads.
[0005] According to the invention, this problem is solved by a
pre-fabricated wall piece with the characteristics given in claim
1. Other advantageous embodiments are described in the
subclaims.
[0006] According to the invention, the reinforcement connecting the
inner and the outer wall of the pre-fabricated wall piece proposed
by the invention comprises U-shaped connector pins made of steel
whose web is held in the outer wall. In addition, the
pre-fabricated wall piece proposed by the invention comprises a
lattice beam reinforcement that projects from the inner side of the
inner wall facing the outer wall into a cavity between the inner
and the outer wall that is to be filled with concrete on site. The
connector pins are spaced in the concrete of the outer wall, and
their front tips are embedded in the concrete of the inner wall.
They serve for the horizontal positioning of the outer wall
relative to the inner wall. In order to ensure a sufficient
transfer of tensile forces, the front tips of the connector pins
have a wavy shape. In addition to the inner wall of the
pre-fabricated wall piece, this makes it possible to give the outer
wall load-bearing capacities, too, so that it can also serve
without restrictions for load transfer purposes. For example, it
now becomes possible to place the outer wall of pre-fabricated
houses directly above the outer wall of the pre-fabricated wall
piece forming the basement wall, thereby transferring the load of
the outer wall of the pre-fabricated house directly to the outer
wall of the pre-fabricated wall piece proposed by the invention.
Preferably, the connector pins connecting the outer and the inner
wall are made of a non-rusting material like stainless steel (V2A,
V4A) or hot-galvanized steel in order to prevent them from rusting
through over time. The distance the lattice-beam reinforcement
projects from the inner wall projects into the cavity between the
inner wall and the outer wall may vary. It may end before reaching
the insulating layer, it may end at this layer, or may also enter
into this layer for a short distance. When the cavity is filled
with concrete, it is embedded in the concrete and provides a
shear-proof connection of the cured concrete and the inner wall of
the pre-fabricated wall piece.
[0007] Preferably, the lattice-beam reinforcement embedded in the
concrete of the inner wall extends all the way to the insulating
layer of the outer wall. The lattice beams are arranged evenly
spaced over the length of the pre-fabricated wall piece, reaching
from the lower end to the upper end of the pre-fabricated wall
piece. The lattice beams do not penetrate the insulating layer of
the outer wall, and are not connected with the outer wall. This has
the advantage that there is no heat transfer via the lattice beams
between the inner and the outer wall, which improves the thermal
insulation. For support, the outer wall of the pre-fabricated wall
piece rests on a foundation (concrete support, bed of mortar)
because the connection of the outer wall and the inner wall via the
connector pins is not sufficiently shear-proof. This makes it
possible to transfer vertical loads to the outer wall. The
lattice-beam reinforcement may consist of steel without corrosion
protection.
[0008] Preferably, the upper end of the outer wall comprises a row
of connector pins serving as connection reinforcement, with the
free ends of the connector pins projecting into the space of a
joint with a ceiling element. The wavy tips of the connector pins
augment the reinforcement of the ceiling element resting on the
inner wall; after the ceiling element has been filled with
concrete, they provide a shear-proof connection of the outer wall
with the ceiling element.
[0009] Below, the invention is explained in detail with the help of
an embodiment shown in the drawing. Additional characteristics of
the invention can be found in the following description of the
embodiment of the invention in conjunction with the claims and the
attached drawings. The individual characteristics may be
implemented either by themselves or in combination with others in
various embodiments of the invention.
[0010] FIG. 1 shows a schematic section of the pre-fabricated wall
piece as proposed by the invention; and
[0011] FIG. 2 shows a schematic side view of the pre-fabricated
wall piece shown in FIG. 1.
[0012] As shown in FIG. 1 and FIG. 2, the embodiment of the
core-insulated pre-fabricated wall piece 1 proposed by the
invention consists of two factory-made walls 3, 4 that are spaced
and connected by connector pins 2 made of stainless steel. Between
the outer wall 3 and the inner wall 4, there is a cavity 5 that is
filled with concrete 19 at the construction site. A thermal
insulation layer 8 made of expanded polyurethane or polystyrene is
applied to the inner side 6 of the outer wall 3. As installed at
the factory, the connector pins 2 serve to accept the horizontal
forces from the fresh-concrete pressure of the on-site concrete
filling 19, and, in completed condition, for the horizontal
positioning of the outer wall 3 relative to the inner wall 4. A
shear-proof connection between the inner wall 4 and the on-site
concrete core is established by the lattice beams 9. Ex factory,
the lattice beams 9 are embedded in the inner wall 4 and extend all
the way to the thermal insulation layer 8. The lattice beams 9
extend from the lower end 10 to the upper end 11 of the
pre-fabricated wall piece 1 and are arranged with a spacing of
.ltoreq.62.5 cm over the length of the inner wall 4. However,
unlike conventional pre-fabricated wall pieces with core
insulation, the lattice beams 9 do not connect the outer wall 3
with the inner wall 4 of the pre-fabricated wall piece 1, and
therefore do not assume a stabilizing function for the outer wall 3
of the pre-fabricated wall piece 1. Consequently, the outer wall 3
rests on a concrete support 12 placed on a bottom 13. At the upper
end 11 of the pre-fabricated wall piece 1, transportation lugs 14
connected with the outer wall 3 and the inner wall 4 are provided.
The transportation lugs 14 form a shear-proof connection between
the inner wall 4 and the outer wall 3 that is only effective during
transportation and assembly and prevents the walls 3, 4 from
shifting relative to each other. When the cavity 5 of the
pre-fabricated wall piece 1 is filled with concrete 19 on site, the
transportation lugs 14 may be embedded in place. The outer wall 3
is self-bearing and has a wall thickness of approximately 8 cm. In
this design, the inner wall 4 has a thickness of approximately 6
cm. Depending on the desired thermal insulation effect, the thermal
insulation layer 8 is between 2 and 12 cm thick and the cavity 5 is
10 cm wide in order to ensure the sufficient stability of the
pre-fabricated wall piece 1. The connector pins 2 are evenly
distributed over the surface of the pre-fabricated wall piece 1,
and spaced approximately 50 to 60 cm from each other. They are
U-shaped and have wavy tips. The webs of the connector pins 2 are
embedded in the outer wall 3, and their wavy tips are embedded in
the inner wall 4, penetrating the thermal insulation layer 8.
Typically, the connector pins 2 have a diameter of 5 mm. In order
to stabilize the pre-fabricated wall piece 1, connector pins 2 with
a diameter of 8 mm can be used for the lowermost row of connector
pins 15. At the upper end 11 of the pre-fabricated wall piece 1, an
uppermost row of connector pins 16 is provided as connecting
reinforcement with a ceiling element 17. The webs of the connector
pins 2 of the uppermost row of connector pins 16 are embedded in
the outer wall 4, with their free ends projecting into the space of
a joint 20 with the ceiling element 17. The row of connector pins
16 is embedded when the ceiling element 17 is filled with on-site
concrete 18 and thereby establishes a tension-proof and shear-proof
connection of the outer wall 3 with the ceiling element 17.
[0013] The manufacture of the pre-fabricated wall piece 1 described
above proceeds as follows: after the concrete of the outer wall 3
has been placed on a metal plate or similar device, with
simultaneous embedding of the connector pins 2, the thermal
insulation layer 8 is applied to the inner side 6 of the outer wall
3 by means of foaming or the insertion of thermal insulation
panels. After the foam has cured, or after the thermal insulation
panels of the thermal insulation layer 8 have been inserted, the
entire part is turned and, for manufacturing the inner wall 4,
immersed with the free tips of the connector pins 2 that protrude
from the thermal insulation layer 8 into a bed of concrete located
on a metal plate or similar device, with lattice beams 9 inserted
into said bed of concrete, which is then vibrated and allowed to
cure. The placement of concrete for the outer wall 3 and the inner
wall 4 on a metal plate or similar device for the purpose of later
detachment is done in conventional fashion, thereby ensuring a
smooth outer surface of the outer wall 3 as well as of the inner
wall 4 that requires no further processing to achieve the desired
surface quality of the panels.
* * * * *