WO2013037027A1

WO2013037027A1 - Method for manufacturing standardised plastic components, thus manufactured components and assembly of prefabricated houses

Info

Publication number: WO2013037027A1
Application number: PCT/BR2012/000353
Authority: WO
Inventors: Luciano Vinicius DEMARCHI; Elio De Mello Castanho Junior
Original assignee: Demarchi Luciano Vinicius; Mello Cassanho Elio Jr De
Priority date: 2011-09-16
Filing date: 2012-09-14
Publication date: 2013-03-21
Also published as: BRPI1105882A2; BRPI1105882B1

Abstract

A method for manufacturing standardised plastic components, the thus manufactured components and the assembly of prefabricated houses find uses in the field of civil engineering, providing pre-stressed, self-supporting plastic houses with an integral ecological structure formed by an assembly of standardised parts that are made of recycled or non-recycled plastics, are light, thermally and acoustically insulating, fireproof, weather-resistant and resistant to earthquakes, insects, U.V. radiation and decomposition, can be associated with other, conventional components quickly, with a high quality and low manufacturing and maintenance costs, are robust, have an aesthetic appearance and are easy to assemble.

Description

"PROCESS FOR MANUFACTURING PLASTIC STANDARD PARTS, RESULTING PARTS AND ASSEMBLY OF PREFABRICATED HOUSES".

This patent refers to the process of manufacturing standardized plastic parts, resulting parts and assembly process of prefabricated houses, applied in the area of construction, obtaining intended plastic houses, ecological, formed with a set standardized parts of recycled or non-recycled plastics, combined with other conventional parts, with speed, quality, low manufacturing and maintenance costs, robustness, better appearance and ease of assembly.

As is well known by the technical means connected with general construction and prefab construction in particular there are currently various processes and various types of prefabricated parts transported and assembled at the construction site, but they have limitations, drawbacks and disadvantages. costs are cheaper than conventional ones, needs of a variety of non-plastic materials in quantity and diversity for structural purposes and other complementary functions, need for internal and external finishes such as plastering and painting, high weight with consequent high material consumption , difficult to handle due to the use of heterogeneous materials of different densities and geometry and improvisation in the use of recycled materials such as PET bottles and tires, obtaining dubious quality and dubious prefabricated parts demanding and more expensive in the finishing.

Searching the Brazilian and foreign patent banks we find the following patents on this subject: a) Brazilian patent PI0804833-9 Building System for Manufacturing Homes and Other Structures that reveals a new system that was developed for manufacturing houses with closing panels (1) made of plastic or not, recyclable or not, which are fitted between vertical profiles (2) and horizontal profiles (3), locked at the bottom and top by suitable structures. It is more efficient and more practical than existing systems, because it uses vertical (2) and horizontal (3) profiles to fit the closing panels, without the need for a prefabricated metal structure to screw them. However, offering more firmness to the walls, the "building system for the manufacture of houses and other structures" is basically composed of: closing panels (1), vertical profiles (2); horizontal profiles (3), shoes (4), base frames, floor panels (5), metalon profiles (6), shear-type crossbeams (7), strap beams (8), screws, in addition to plumbing / sanitary and electrical.

b) US Patent 6804925 Composite Building Material and Panels made therewith. A composite material that is formed into structural basic panels that can be subsequently mounted to the floor, walls, roof beams, and building roofs by unqualified work access to have basic tools is disclosed. Thus, basic, low-cost housing shelters and various other structures such as schools, churches, clinics and storage facilities can be built to meet the need for such structures in economically distressed countries with large populations. The building material for the panels is a molded polymer made of either homogeneous or non-homogeneous material. The materials mainly consist of recycled or virgin polyolefins, mainly polyethylene and polypropylene compounds with or without various additives, including fiberglass, metals and naturally occurring materials such as rice husk, sugarcane bagasse, nut shells, talc, clay, sand and wood. Ducts and channels for electrical wiring, plumbing, and ventilation can be provided and a ribbed reinforcement grid can be included for strength. Upright or horizontal bars and reinforcing materials including fabrics may also be run through the available channels formed in the composite material to increase structural stability. Each structural panel can be provided with flanges at the ends where holes align with holes in other structural panels for securing the structural panels together using various devices. Sealants, adhesives and flashing can be applied to the interfaces between the structural panels.

c) US Patent US2008307747 Modular Structure for Construction, Panels and Method of Fabrication and Use thereof. The present invention is a system of polymeric panels and the method for production and use, permitting the rapid construction of a building foundation wall or other structure and in particular a foundation below the grid. The polymeric base system includes polymeric wall panels and other components suitable for supporting lateral and end compression loads. The walls include two parallel faces separated by a series of webs or ribs, where the webs and faces of the wall panels may be formed of a similar polymer material, such as polyvinyl chloride (PVC). Wall panels and / or other components may be extruded to allow rapid production of sections of wall panels, where panels may be cut to length and then secured to adjacent panels to form a foundation wall. The method of fixing adjacent panels may include welding, gluing or other techniques and may be performed on the job site or in a prefabrication facility. In addition, the wall panels can be coextruded with an insulating material inserted into the voids between the parallel faces to provide improved thermal performance of the foundation as well.

d) Taiwanese Patent TWI290862 Hardwood Imitative Hardwood Building Material made of Plastic Material and Method for Manufacturing Them. This invention relates to a hardwood imitation building material made of raw discarded plastic material and method for doing the same. The method includes the steps of: grounding dusted phenolic resin sheets mixing the powder with recycled plastic or new plastic such as PE, PVC, PP, PS, ABS, PET, OPP and PMMA subjecting the mixture to mixing, granulation and injection Extrusion or centrifugal molding to obtain the construction material imitated hardwood with beautiful and natural log-like wood grain, high rigid strength, low density and low cost. Most significantly, the building material is a material with low fire, smoke, non flammable, low toxic, and electrical insulated characteristics. It can be recycled for repeated use. The invention utilizes discarded phenolic resin sheets as the raw material which is then mixed with recycled plastic such as PE, PVC, PP, PS, ABS, PET, OPP and PMMA which has been subjected to a recycling treatment. The raw materials with low costs. This invention can recycle discarded waste for recycling purpose, so as to significantly reduce log consumption. This invention provides a highly beneficial environmental benefit and protection with very useful economic values.

e) Japanese patent JP2000308869 Production of recyclable building material using recycled plastic. Problem to be solved: To provide a method for producing recyclable building materials for the second time at low cost using not only PET bottles, regardless of a colored or colorless one, but also all wastes such as polypropylene (PP) PET bottle caps and shells. SOLUTION: Recyclable building materials are produced by feeding plastic waste and shells into a melter, heating in the melter, shaking molten plastics and shells and then mixing PP into the melter after some time and extrusion molding. an extruder.

State-of-the-art disclosures, while bringing many technical solutions and are quite broad, do not offer a proposal for an optimized process using a set of flexible standardized parts for assembling environmentally friendly prefabricated houses and with reduced and rational use of materials.

The problems to be solved with the parts and process of the present patent were as follows:

a) Specifically with respect to Brazilian patent PI 0804833-9, the present patent solved the following problems:

It needs a very heavy metal-framed conventional roof requiring robust metalon support pillars and making the construction more expensive;

Need to use lower beams, pillars and metal upper beams to create a support structure and to fit the plastic plates, increasing the construction and weight of the house;

The plastic panels are hollow injected and internally stuffed with polyurethane for high cost, high cost labor-intensive thermal and acoustic insulation;

The panels are unfinished and require final finishing of plaster or other coating, making the construction more expensive; Electrical and hydraulic pipelines are customized on each panel, creating various types of panels, complicating production and logistics and increasing overall costs;

Uses conventional windows and doors keeping the assembly difficulties and high costs of these items;

It needs a sturdy foundation due to the weight of the final house; and

Excessive use of materials in quantity and variety.

Regarding US patent 6804925 the following issues have been resolved:

It uses metal reinforcements inside the plastic panel to create a supporting structure, making the construction, weight and construction time of the panels more expensive;

The plastic panels are injected hollow not stuffed internally without thermal and acoustic insulation;

The panels are unfinished and require final finishing making the construction more expensive;

Electrical and hydraulic pipelines are customized on each panel, creating various types of panels, complicating production and logistics and increasing overall costs;

Assembly takes time due to the need to screw between the panels;

Use of complex parts that are difficult to assemble and produce to burden the house; and

Excessive use of materials in quantity and variety. "PROCESS FOR MANUFACTURING PLASTIC STANDARD PARTS, RESULTING PARTS AND PREFABRICATED HOUSE ASSEMBLY", object of the present patent, was developed to overcome the drawbacks, limitations and disadvantages of current manufacturing and assembly processes and current parts, because it utilizes an unprecedented design of standardized parts of recycled or non-recycled plastics, associated with other conventional parts, with speed, quality, low manufacturing and maintenance costs, robustness, better appearance and ease of assembly.

Additionally, the processes and parts of the present patent solved the problems of current systems and brought the following advantages:

Lightness for being virtually all plastic;

Features thermal and acoustic insulation due to trapped anechoic air bubbles created within parts during the manufacturing process;

Lower energy expenditure in the manufacture of parts, as it is performed with fewer steps and directly with various types of plastics collected for recycling, without the need for previous accurate selection and pelletizing process;

Lower weight of parts as the process generates extruded, cast and expanded plastic parts with blowing agents using about 1/3 of the weight of rigid plastic. The internal bubbles produced by the blowing agent save plastic by allowing lighter parts to be obtained and allowing optimum thermal and acoustic comfort without the need to fill with foams like high cost polyurethane, as well as more labor to fill. In this system occurs a rigid skin (solid) with expansion only in the center of the piece, similar to light and robust structures such as "HoneyComb", applied to airplane floors to 400kg / cm2;

Practicality and ease of assembly without the need for skilled labor, as the panels are formed from male and female insertable planks, providing the minimum and sufficient thickness to give buckling stability when their elements are compressed by steel tensioners, forming unpublished monolithic walls. It is a wall, not of prestressed concrete but of prestressed plastic, that is, the plastic elements are compressed together to form a monolithic, self-supporting wall;

Economy in the internal and external finishing, because the walls obtained are colored already in the manufacturing process and able to integrate the structural aspect of the construction linking all the panels (walls, ceiling and floor) by tensioners producing a lightweight, economical parallelepiped or prism. of material and rigid enough to resemble a monocoque structure, without the need for interstitial adhesives, sealants, paints or plasters;

8. Incombustibility, as the blocks are still used flameproof additives;

9. Lower cost per ease of logistics, ease of assembly, efficiency of production of parts, use of less material weight and very little maintenance, with consequent use of less manpower and raw materials, as the design and parts used are mostly obtained from the same blend of recycled plastic with a small variety of materials and a group of standardized parts, including windows and doors and their respective frames; 10. Quality of construction, because the house obtained is resistant to weather, earthquakes, insects, UV radiation and rot, with a neat finish;

1 1. Aesthetic beauty, as it can be built from architectural design; and

12. Ecological, fully sustainable through the use of recycled material, energy saving, prevents the growth of dumps.

For better understanding of the present patent the following drawings are attached:

FIGURE 1, showing the perspective of a home obtained with the process and modular parts of the present invention;

FIGURE 2, showing perspective, left side view, rear view, and bottom view of the basic board of the present invention;

FIGURE 3 showing perspective, left side view, rear view and top view of the junction board of the present invention;

FIGURE 4 showing perspective, left side view, rear view and top view of the corner board of the present invention;

FIGURE 5 showing perspective, left side view, rear view, and bottom view of the female adapter plate of the present invention;

FIGURE 6, showing perspective, left side view, rear view, and bottom view of the male adapter plate of the present invention; FIGURE 7 showing perspective, left side view, rear view and top view of the stop of the present invention;

FIGURE 8, showing perspective, left side view, rear view, and top view of the male wide board of the present invention;

FIGURE 9 showing perspective, left side view, rear view and bottom view of the female wide board of the present invention;

FIGURE 10, showing perspective, left side view, rear view, and top view of the connecting board of the present invention;

FIGURE 11 showing perspective, left side view, rear view, and bottom view of the tile of the present invention;

FIGURE 12 showing perspective, left side view, rear view and top view of the ridge of the present invention;

FIGURE 13 showing perspective, left side view, rear view, and bottom view of the closure board of the present invention;

FIGURE 14, showing the top view of placing the ties on the boards of the process of the present invention;

FIGURE 15 showing the perspective of placing the ties on the boards of the process of the present invention;

FIGURE 16 showing the perspective view of a monolithic panel with implanted tie rod of the process of the present invention; FIGURE 17, showing the perspective view of a monolithic panel with tie rod door and window frames of the process of the present invention;

FIGURE 18 showing the perspective of the house floor-to-ceiling connection of the process of the present invention;

FIGURE 19 showing the perspective of assembling the lined and one-door house of the process of the present invention;

FIGURE 20 showing the perspective of mounting the roof structure of the process of the present invention;

FIGURE 21, showing the perspective of the roofed house placed, without closing the eighth with the process of the present patent; and

FIGURE 22, showing the perspective of the house with the locks of the eighth with the process of the present patent.

According to the aforementioned figures, the standard parts set of the present invention is comprised of a prismatic rectangular base plate (1) with a male socket (1-A) and opposite female socket (1-B), hollow with longitudinal holes (1-C) and horizontal transverse holes (1-D) and made of extruded plastic; Rectangular T-shaped junction plate (2) with two sides with male fittings (2- A) and one female socket side (2-B), hollow with longitudinal holes (2-C) and horizontal transverse holes (2-D) and vertical transverse holes (2-E) and constructed of extruded plastic; Rectangular "L" shaped prismatic corner plank (3) with one male insert side (3-A) and one female insert side (3-B) and hollow with longitudinal holes (3-C), horizontal transverse holes (3-D) and vertical transverse holes (3-E) and made of extruded plastic; female fitting plate (4) of rectangular prismatic shape with two female fittings (4-B), cast with a longitudinal hole (4-C) and transverse holes (4-D) and made of extruded plastic; male fitting plate (5) of rectangular prismatic shape with two male fittings (5-A), cast with longitudinal holes (5-C) and horizontal transverse holes (5-D) and made of extruded plastic; threaded rods (6) with conventional washers (6-A) and nuts (6-B); female prismatic rectangular C-shaped stop (7) with female socket (7-Bl) at the bottom and female socket (7-B-2) at the top and made of extruded plastic; male wide plank (8) of prismatic rectangular shape with male fitting (8-A) on one side and horizontal transverse holes (8-D) and constructed of extruded plastic; female wide plate (9) of prismatic rectangular shape with female socket (9-B) on one side and horizontal transverse holes (9-D) and constructed of extruded plastic; rectangular "T" shaped prismatic male profile (10) with one side with male insert (10-A), hollow with longitudinal hole (10-C) and made of extruded plastic; corrugated tile (11) constructed of extruded plastic; ridge (12) straight saddle-type saddle to seal shingles junction (12-A) and curved to seal shingle wave depressions (12-B); prismatic rectangular V-shaped ridge cap (13); closing board (14) of rectangular prismatic shape and constructed of extruded plastic; conventional retaining plate for the house (15); and conventional window (not shown in the figures).

The manufacturing process of standardized extruded plastic parts is carried out as follows:

(a) selection of recycled plastic waste when recycled plastic is used; b) Mixing and dosing of plastic materials for blending;

(c) One-step extrusion of recycled or non-added plastics with blowing agents, dyes, flame-retardant and ultraviolet additives and cutting and obtaining extruded plastics cast into expanded plastic with about 1 / 3 the weight of the rigid plastic and forming a massive rigid skin with expansion only in the core of the piece;

d) cooling of parts; and

e) Transverse drilling of parts (1), (2),

(3), (4), (5), (8) and (9).

The assembly of the prefab of the present patent is carried out as follows:

1) The foundation is prepared, such as radier, baldrame beam or any other;

2) Assemble the floor by placing several basic planks (1) and passing through the tie rods (6) and tightening with washers (6-A) and nuts (6-B) at the ends, obtaining a monolithic panel (PMPI). ) which is drilled in some parts to pass utility ducts and will form the floor;

3) Assemble the monolithic panels (PMPA) that will compose the outer and inner walls using basic planks (1) and / or junction planks (2) and / or corner plank (3) and / or female adaptation plank ( 4) and male adaptation plate (5) and / or miter profile (7) and its rods (6) placed transversely;

4) The monolithic panels (PMPA) that compose the outer and inner walls are joined using the junction boards (3) and corner board (4) and their transversely placed risers (6) and diagonal risers (6) at the corners; 5) The monolithic panel (PMPI) is secured to the monolithic panel (PMPA) floor with vertical (6) tie rods and diagonal (6) tie rods;

6) Assemble the slab by placing several basic planks (1) and passing through the tie rods (6) and tightening with washers (6-A) and nuts (6-B) at the ends, obtaining a monolithic panel (PMLA). ) which is drilled in some parts for the passage of utility ducts and will form the slab;

(7) The monolithic panel (PMLA) is secured to the monolithic panel (PMPA) with vertical (6) and diagonal (6) tie rods;

8) Utility pipes are routed through holes (1-C), (2-C), (3-C), (4-C) and (5-C) of parts;

9) The roof structure is assembled by stacking basic planks (1) with a junction plank (2) at the bottom and a connecting plank (10) at the top by piercing (6) forming monolithic panels (PMPE) which form the hangers which are linked together by inclined basic planks (1);

10) Monolithic panel (PMPE) junction boards (2) are screwed into the monolithic panel (PMPA) and monolithic panel (PMLA);

11) Place the tiles by screwing them into the connecting boards (10) of the monolithic panels (PMPE) and attaching the ridge caps (12) and the ridge closure piece (13);

12) The eighths are closed with the closing planks (14) by screwing them into the inclined basic planks (1) of the roof structure; and 13) The house is fixed to the foundation by plates

(15).

The standard parts of the present invention are of sufficient thickness to give buckling stability when their elements are compressed by steel tensors, forming unprecedented monolithic walls. It is a wall, not of prestressed concrete, but of prestressed plastic, that is, the plastic elements are compressed together to form a monolithic, self-supporting wall.

The obtained walls are capable of integrating the structural aspect of the construction by linking all the panels (walls, ceiling and floor) by tensors producing a lightweight parallelepiped or prism, economical in amount of material and rigid enough to resemble a monocoque structure.

Features thermal and acoustic insulation due to trapped anechoic air bubbles created within parts during the manufacturing process.

The obtained walls are capable of integrating the structural aspect of the construction by linking all the panels (walls, ceiling and floor) by tensors producing a lightweight parallelepiped or prism, economical in amount of material and rigid enough to resemble a monocoque structure. Features thermal and acoustic insulation due to trapped anechoic air bubbles created within parts during the manufacturing process.

Claims

1. "MANUFACTURING PROCESS

PLASTIC PATTERN PARTS, RESULTING PARTS AND ASSEMBLY OF PRE-MANUFACTURED HOUSES ", characterized by:

a) Process of manufacturing standard parts in the following sequence:

a) Selection of recycled plastic waste; b) Mixing and dosing of plastic materials for blending;

(c) One-step extrusion of recycled or non-added plastics with blowing agents, dyes, flame-retardant additives and ultraviolet additives and cutting and obtaining extruded plastic parts cast into about 1/2 expanded plastic. 3 the weight of the rigid plastic and forming a massive rigid skin with expansion only in the core of the piece;

d) cooling of parts; and

e) Transverse drilling of parts (1), (2),

(3), (4), (5), (8) and (9);

b) Obtaining the following standard parts:

base plate (1) of rectangular prismatic shape with one side with male insert (1-A) and opposite side with female insert (1-B), cast with longitudinal holes (1-C) and horizontal transverse holes (1-D) and made of extruded plastic; Rectangular T-shaped junction plate (2) with two sides with male fittings (2-A) and one female socket side (2-B), hollow with longitudinal holes (2-C), horizontal transverse holes (2-D), vertical transverse holes (2-E) and constructed of extruded plastic; Rectangular "L" shaped prismatic corner plank (3) with one male insert side (3-A) and one female insert side (3-B) and hollow with longitudinal holes (3-C), horizontal transverse holes (3-D) and vertical transverse holes (3-E) and made of extruded plastic; female fitting plate (4) of rectangular prismatic shape with two female fittings (4-B), cast with a longitudinal hole (4-C) and transverse holes (4-D) and made of extruded plastic; male fitting plate (5) of rectangular prismatic shape with two male fittings (5-A), cast with longitudinal holes (5-C) and transverse holes (5-D) and made of extruded plastic; threaded rods (6) with conventional washers (6- A) and nuts (6-B); female prismatic rectangular C-shaped stop (7) with female socket (7-Bl) at the bottom and female socket (7-B-2) at the top and made of extruded plastic; male wide plank (8) of prismatic rectangular shape with male fitting (8-A) on one side and horizontal transverse holes (8-D) and constructed of extruded plastic; female wide plate (9) of prismatic rectangular shape with female socket (9-B) on one side and horizontal transverse holes (9-D) and constructed of extruded plastic; rectangular "T" shaped prismatic male profile (10) with one side with male insert (10-A), hollow with longitudinal hole (10-C) and made of extruded plastic; corrugated tile (11) constructed of extruded plastic; ridge (12) straight saddle-type saddle to seal shingles junction (12-A) and curved to seal shingle wave depressions (12-B); prismatic rectangular V-shaped ridge cap (13); closing board (14) of rectangular prismatic shape and constructed of extruded plastic; and c) House assembly in the following sequence:

1) The foundation is prepared, such as radier, baldrame beam or any other;

4) The monolithic panels (PMPA) that make up the outer and inner walls are joined using the junction boards (3) and corner board (4) and their transversely placed tie rods (6) and diagonal tie rods (6) (not shown). in the figures) in the corners;

5) The monolithic panel (PMPI) is secured to the monolithic panel (PMPA) floor with vertical (6) risers and diagonal (6) risers (not shown in the figures);

6) Assemble the slab by placing several basic planks (1) and passing through the tie rods (6) and tightening with washers (6-A) and nuts (6-B) at the ends, obtaining a monolithic panel (PMLA). ) which is drilled in some parts for the passage of utility ducts and will form the slab; 7) Lock the monolithic panel (PMLA) on the monolithic panel (PMPA) with vertical (6) and diagonal (6) tie rods (not shown in the figures);

12) The eighths are closed with the closing planks (14) by screwing them into the inclined basic planks (1) of the roof structure; and

13) The house is fixed to the foundation by slabs

(15).

2. "MANUFACTURING PROCESS

PLASTIC STANDARD PARTS "according to claim 1, characterized by low energy expenditure in the manufacture of parts with fewer steps and directly with various types of plastics collected for recycling, without the need for a previous accurate selection and pelletizing process.

3. "STANDARDIZED PARTS

PLASTICS "according to claim 1, characterized in that they have a minimum and sufficient thickness to give buckling stability.

"PLASTIC STANDARDIZED PARTS" according to claim 1, characterized in that they are lightweight and have thermal and acoustic insulation due to trapped anechoic air bubbles created within the parts during the manufacturing process.

5. "STANDARDIZED PARTS

PLASTICS "according to claim 1, characterized in that they are colored and with a neat finish already in the manufacturing process.

6. "PLASTIC STANDARDIZED PARTS" according to claim 1, characterized in that they are environmentally friendly, non-combustible, weatherproof, earthquake, insect, UV radiation and rotting resistant.

"PREFABRICATED HOUSE ASSEMBLY PROCESS" according to claim 1, characterized in that, when their elements are compressed by steel tensioners, they will form self-supporting, similarly protected, monolithic walls of a monocoque structure.