Modular elements, network, supporting structure, construction and process for obtaining thereof

The invention relates to modular elements made of insulating materials for constructions, provided with at least one network element in the interior; to a network obtained by connecting modular elements; to a supporting structure achieved by casting a hardening material in the network achieved by connecting the modular elements and joining them through the supporting structure, as well as to the process for obtaining thereof.

The concrete panels are used in a wide range of applications in the civil engineering industry, the construction time being thus reduced. The pre-cast panels are manufactured by casting the concrete into forms (concrete forming).After hardening, the panels are vertically positioned at the construction site.

Since the panels are not insulated there is an disadvantage in insulating them at a later stage, as insulating operations are expensive and imply a lot of manual working.

Another disadvantage is they could not be used for ceilings, as they have not sufficient strenght in the case of large-sized ceilings.

The patent US2002017070 describes an expanded plastic module intended for the building of a concrete wall structure, insulated by interconnecting the modules and filling them with concrete.The module is made of expanded polystyrene. Each module has the form of a rigid block, having an interior configuration designed to be filled with concrete. Aditionally, for the increase of strenght, a network of steel or plastic bars is being introduced inside the modules.The disadvantage of this technical solution consists in a high rate of concrete consumption, flow problems upon the placing of concrete, due to the internal channels, positioned perpendiculary along the vertical and horizontal line; also, a too complex construction and aditional manual working, brought about by the network of bars.

The patent WO2005059264 relates to polyurethanes or polystyrene foams for concrete structures.

The insulating blocks elements have an interior arrangement in the form of vertical cavities in a trapezoidal, circular, elliptical or parabolic shape.The structure obtained after the blocks have been filled with concrete has good strenght properties and optimum heat insulation. The disadvantage of this technical solution consists in a high rate of isolation material and concrete consumption; moreover, the strenght of the linear structure is inferior to the structures in which concrete is cast in several directions.

The patent US4942707 describes ceiling or roof structures, based on a rigid insulation, provided with several cavities or channels that become molds for the concrete during its casting. Following the joining of structures in the form of a ceiling or a roof, concrete is to be cast in these cavities or channels. The disadvantage of this technical solution is the high rate of consumption of concrete; also, it may be applied only to ceilings and roofs.

Another major disadvantage of insulating elements with interior channels for casting of concrete is that they become only elements of a building, such as walls, ceilings, not being able to meet the necessary features for obtaining an appropriate supporting structure for a complete construction.

The problem solved by this invention is the achievement of a construction with a unitary structure of strenght and appropriate heat insulation, withouth any elements of concrete forming, using a simple and cost effective procedure.

The purpose of this invention is the achievement of a unitary supporting structure that would be suitable for constructions, through the casting of a hardening material in a unitary network, defined and formed through the connection of modular elements made of insulating materials.

In accordance with one embodiment of the present invention, the modular element removes the previously mentioned disadvantages, as it has an interior network element made up of at least two main half-joints and at least two secondary half-joints, connected through vertical , horizontal and oblique channels.

In accordance with another embodiment of the present invention, the modular element removes the previously mentioned disadvantages, as it has an interior network element made up of two main half- joints and two secondary half-joints, connected through vertical, horizontal and oblique

channels.In accordance with another embodiment of the present invention, the modular element removes the previously mentioned disadvantages as it has an interior network element made up of three main half-joints and three secondary half-joints, connected through vertical, horizontal and oblique channels.

In accordance with another embodiment of the present invention, the modular element removes the previously mentioned disadvantages as it has an interior network element made up of five main half-joints and five secondary half-joints, connected through vertical, horizontal and oblique channels.

In accordance with another embodiment of the present invention, the modular element removes the previously mentioned disadvantages, as it has an interior network element made up of four main half-joints and four secondary half-joints, connected through vertical, horizontal and oblique channels.

According to the invention, the modular elements have an even or odd number of half joints.

In accordance with one embodiment of the present invention, the network obtained by assembling the modular elements removes the previously mentioned disadvantages as it is made up of main and secondary joints, connected through vertical, horizontal and oblique channels.

In accordance with another embodiment of the present invention, the unitary supporting structure removes the above mentioned disadvantages, as it is obtained by casting a material that will harden in the unitary network for the entire construction.

In accordance with another embodiment of the present invention, the construction removes the previously mentioned disadvantages as it is made up of a unitary supporting structure inside of an insulating structure, obtained by connecting the modular elements.

In accordance with another embodiment of the present invention, the process for obtaining the construction according to the invention removes the disadvantages mentioned above as it consists of the following: connection of the modular elements and the casting of the material that hardens in the network defined through the connection of the modular elements and the creation of a unitary supporting structure.

According to the invention, the modular elements are made of synthetic foams based on polyurethanes, polyimides, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, amino resins, phenolic resins, silicones, expanded polystyrene and sodium silicate.

The network elements are joints having a cylindrical, spherical, prismatic or tapered form, connected through vertical, oblique or horisontal channels, as well as open channels which intersect each another perpendicularly.

The material to be cast in the network according to the invention, in order to harden and form the supporting structure may be one of the followingiconcrete, reinforced concrete, polyesther resins, epoxy resins, polyurethane resins.

For example, the construction procedure for one-floor building includes the connection of modular elements for the foundation, walls, ceiling, roof in a vault shape and the cast of material in the network defined by specific modular elements: the material hardens and forms the supporting structure which is unitary in the building assembly, but specific for each part of the building.

A main joint is defined as the geometrical position determined by the intersection of vertical, horizontal and oblique channels.

A secondary joint is defined as the geometrical position determined by the intersection of vertical, horizontal and oblique channels.

A main half-joint is defined as a part from a main half-joint.

A secondary half-joint is defined as a part from a secondary half-joint.

A network element is defined as a part from a network obtained by assembling the modular elements.

The following advantages are obtained by the application of this invention:

- the achievement of a construction with a unitary structure of strenght and appropriate heat insulation, withouth any elements of concrete forming, using a simple and cost effective procedure

- the construction is achieved in shorter time in comparison with traditional processes;

- the resistance of the construction is higher in comparison with other processes;

- the modular elements adapt horizontally and vertically.

An example of achievement of the invention is given below in conjunction with 1-7 drawings, wherein:

Fig.l . Modular element (1) having in interior a network element consisting of two main half-joint (2) and two secondary half-joints (3) connected through vertical channels (4), horizontal channels (5) and oblique channels (6) and eight joint elements (7).

Fig.2. Modular element (8) having in the interior a network element consisting of three main half- joints (2), three secondary half-joints (3) connected through vertical channels (4), horizontal channels (5) and oblique channels (6) and twelve joint elements (7).

Fig.3. Modular element (9) having in the interior a network element consisting of five main half- joints (2) and five secondary half-joints (3) connected through vertical channels (4), horizontal channels (5) and oblique channels (6) and ten joint elements (7).

Fig.4. Modular element (10) having in the interior a network element consisting of four main half- joint (2) and four secondary half-joints (3) connected through vertical channels (4), horizontal channels (5) and oblique channels (6).

Fig.5. Modular element (11) for the corner, having in the interior three main half joints (2), three secondary half-joints (3) connected through vertical channels(4) ), horizontal channels (5) and oblique channels (6).

Fig.6. Modular element (12) for the ceiling having in the interior five main half joints (2) and five open secondary half-joints (3).

Fig.7. Construction consisting of modular elements, making up two exterior walls (13) and an interior wall (14).

Example 1 : There are achieved modular elements for wall (Fig. 2), corner (Fig. 4,5), from fireproofed polyurethane foam, by injecting in mould and expanding at the dimensions of the mould.

The modular elements have the following dimensions: the modular element for wall (Fig. 2) has the dimensions 120/60/30 cm with vertical channels of 20 cm in diameter, horizontal channels of 20 cm in diameter and oblique channels of 18 cm in diameter. the T shaped modular element (Fig. 4) has the dimensions 120/60/60 with 30 cm thickness, with vertical channels of 20 cm in diameter, horizontal channels of 20 cm in diameter and oblique channels of 18 cm in diameter. the modular element for corner (Fig. 5) has the dimensions 60/60/30 cm with vertical channels of 20 cm in diameter, horizontal channels of 20 cm in diameter and oblique channels of 18 cm in diameter.

There is achieved with modular elements the construction presented in Fig.7 as following: the modular elements for exterior wall 13, interior wall 14, T shaped and corner elements are assembled, followed by the casting of concrete B 300 with high fluidity in the formed network.

After hardening, the strenght of the wall at stress is 100 tons/ meter and at critical shear stress is 40 tons.